Fireproofing Specification

FIREPROOFING SPECIFICATION FOR THE

CARTAGENA REFINERY EXPANSION PROJECT

CB&I CONTRACT NO. 166000 Prepared By:

Mechanical Engineering, Houston, TX Document No: 166000-000-SP-MU10-0019

Information Class: Revision Number

Revision Date

0

24-Mar-08

1

Confidential

Business

Revision Description

Public Prepared By:

Checked By:

Approved By:

ISSUED FOR DESIGN

TAA

KRS

KRS

25-Jun-08

ISSUED FOR DESIGN

TAA

SAA

IAR

2

27-Feb-09

ISSUED FOR DESIGN

DD

JB

HT

3

29-Apr-09

ISSUED FOR DESIGN

DD

JB

HT

4

29-Jun-10

ISSUED FOR DESIGN

DD

JB

KDB

5

07-Oct-10

ISSUED FOR CONSTRUCTION

DD

JB

GAD

6

07-Jan-11

ISSUED FOR CONSTRUCTION Incorporated Client’s Comments

DD/JBB

KDB

GAD

7

29-Jul-11

ISSUED FOR CONSTRUCTION

DD/JBB

KDB

GAD

Included Pitt-Char Fireproofing per Client’s request

THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.

Document No.: 000-SP-MU10-0019 Revision: 7

FIREPROOFING SPECIFICATION Date: 29-JUL-2011 Page: 2 of 48

TABLE OF CONTENTS 1.0

INTRODUCT INTRODUCTION......... ION............... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ .........3 ...3 1.1 Purpose Purpose ............ .................. ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............3 ......3 1.2 Scope........... Scope................. ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............3 ......3 1.3 Seller Seller Responsibil Responsibility..... ity........... ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............3 ......3 2.0 REFERENC REFERENCES.......... ES................ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ...........3 .....3 2.1 Intern Internati ationa onall Protec Protectiv tive e Coatin Coating g / Akzo Nobel........ Nobel........... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ......4 ...4 2.2 PPG............... PPG..................... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ...........4 .....4 3.0 DEFINITI DEFINITIONS.. ONS........ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ .........4 ...4 3.1 Hazardous Hazardous Equipmen Equipmentt and Piping Piping ............ .................. ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ .......4 .4 3.2 Hazardous Hazardous Area...... Area............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ .......5 .5 3.3 Fire Protection Protection (Fire (Fire rating) rating)...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............5 ......5 4.0 REQUIRE REQUIREMENT MENTS S ............ .................. ............ ............ ............ ............ ............ ............ ............ ........... ........... ............. ............. ............ ............ ............ ............ ............ .........5 ...5 4.1 Extent Extent of Fireproof Fireproofing.. ing........ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ .......5 .5 5.0 PAINTING PAINTING...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ .........7 ...7 6.0 MATERIAL..... MATERIAL........... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ..........7 ....7 6.1 Concre Concrete te or or Light Lightwei weight ght Concre Concrete: te: Form Form Plac Placed ed Meth Method od and and Pneum Pneumati atical cally ly Applied .........................................................................................................................7 6.2 Lightweig Lightweight ht Cementitio Cementitious us Products Products...... ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ..........8 ....8 6.3 Intume Intumesce scent nt Masti Mastic c (See (See Appe Appendi ndix x A and B for for Mater Material ial Requir Requireme ements nts)) ...... ......... ...... ...... ....8 .8 6.4 Reinforcem Reinforcement...... ent............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ .........9 ...9 6.5 Waterproof Waterproof Mastic....... Mastic............. ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ........9 ..9 7.0 INSTALLAT INSTALLATION ION ............ .................. ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............9 ......9 7.1 Concrete Concrete Fireproofi Fireproofing ng ............ .................. ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ........9 ..9 7.2 Lightweig Lightweight ht Cementitio Cementitious us Fireproofi Fireproofing.. ng........ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............10 ......10 7.3 Intume Intumesce scent nt Mast Mastic ic Fire Firepro proofi ofing ng (See (See Appendi ppendix x A and B for for Appl Applica icatio tion n Requirements)............................................................................................................10 8.0 WORKMANSHI WORKMANSHIP P ............ .................. ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........11 ..11 8.1 Preparatio Preparation.......... n................ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ .......11 .11 8.2 Curing Curing ............ .................. ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ .......11 .11 ATTACHMENTS.................................................................................................................................11 APPENDIX A – APPLICATION APPLICATION OF INTUMESCENT INTUMESCENT FIREPROOFING FIREPROOFING ............................................17 APPLICATION APPLICATION OF CHARTEK 1709................................................................................................... 17 APPENDIX B – APPLICATION APPLICATION OF INTUMESCENT INTUMESCENT FIREPROOFING FIREPROOFING ............................................33 APPLICATION APPLICATION OF PITT-CHAR PITT-CHAR XP ....................................................................................................33




1.0

INTRODUCTION 1.1

Purpose The intent of this standard is to establish a guide for determining which structural steel supports and equipment supports should receive fire protection with the objectives of minimizing danger to personnel fighting fire, spread of fire and damage to process equipment.

1.2

Scope This specification together with the referenced engineering drawings covers the minimum requirements for the materials and application of fireproofing for hazardous equipment, structural steel elements, power and instrument cables and control valves within fire hazardous areas of the plant.

1.3

2.0

1.2.1

Fire proofing proofing material material for structura structurall steel steel members members shall shall be Chartek Chartek 1709 or Pitt-Char Pitt-Char XP. Appendix Appendix A and Appendix B are added to this specification specification to cover requirements requirements for application application of both intumescent intumescent fireproofing. fireproofing.

1.2.2 1.2.2

All struc structura turall steel steel includin including g module module steel steel shall shall receive receive intu intumesc mescent ent mastic mastic firep fireproo roofing fing (See Appendix A and Appendix B).

1.2.3 1.2.3

Vessel Vessel skirts skirts and and saddles saddles shall shall be firepr fireproof oofed ed with norma normall weight weight concre concrete. te.

Seller Responsibility 1.3.1

Any conflict conflict between the requireme requirements nts of this this specifica specification tion and and related related codes, codes, standards, standards, data sheets, drawings, requisition, etc., shall be referred to Purchaser for clarification/resolution.

1.3.2 1.3.2

Suppli Supplier er shall shall not make make assump assumption tions s for informat information ion not not furnishe furnished d by Purchase Purchaser. r. Supplier is required to obtain necessary information from Purchaser or other reliable sources. Any and all claims arising from lack lack of knowledge of required information will be rejected by Purchaser.

1.3.3 1.3.3

Except Exception ions s or variation variations s shown in the Projec Projectt Specifica Specification tions s take precede precedence nce over over requirements shown herein. No variations from the Project Specification and this design standard are permitted unless approved in writing.

REFERENCES Codes and Standards The following documents, including applicable addenda, constitute a part of this specification as described herein. The referenced edition of these documents shall be that which is in effect as of the issue date of this specification. specification. API

American Petroleum Instit ute Publ Publ 2218 2218

ACI

Fire Firepr proo oofi fing ng Prac Practi tice ces s in in Pet Petro role leum um and and Pet Petro roch chem emic ical al Proc Proces essi sing ng Plants-Second Edition American Concrete Institut e




Std. 31 318

Building Co Code Re Requirement fo for Re Reinforced Co Concrete

Std. 506

Guide to Shotcrete

ASTM

American Society of Testing and Mater ials C33

Specification for Concrete Aggregates

C150

Specification for Portland Cement

D695

Test Method for Compressive Properties of Rigid Plastics

D790

Test Method for Flexural Properties of Unreinforced Plastics & Electrical Insulation

D2240

Test Me Method for Ru Rubber Pr Properties – Durometer Ha Hardness

D4541

Test Method for Pu Pull-Off St Strength of Coatings Using Portable Testers

E84

Test for Surface Burning Characteristics of Building Materials

UL

Underwriters Laboratories UL 17 1709

SSPC

2.1 2.1

2.2

Steel Structures Painting Council AB-1

Abrasive Grade 1 or 2

PA-2

Measurement of Dry Paint Thickness with Magnetic Gages

SP-1

Solvent Cleaning

SP-6

Commercial Blast Cleaning

SP-7

Sweep Blast Cleaning

SP-10

Near-W hite Blast Cleaning

Inte Intern rnat atio iona nall Pro Prote tect ctiv ive e Coat Coatin ing g / Akz Akzo o Nob Nobel el C1709 APP MAN UK, Rev.0

Application Manual for Chartek 1709

Fire Protect Protection ion QC MAN GB, Rev. Rev. 4

Quality Quality Control Control Manual Manual Systems Application

for

Chartek Chartek

Fireproo Fireproofing fing

PPG Pitt Pitt-C -Cha harr XP

3.0

UL St Standard for for Sa Safety Rapid Rise ise Fi Fire Tests of Pro Prottectio tion Ma Materia rials fo for Structural Steel-Third Edition, Reprint with Revisions Through and Including April 6, 2007

Proj Projec ectt Appl Applic icat atio ion n Manu Manual al

DEFINITIONS 3.1 3.1

Haza azardou rdous s Equi quipmen pmentt and and Piping ping Hazardous equipment and piping is defined (for fireproofing) as that which contains material that is flammable, toxic or dangerous to personnel.



FIREPROOFING SPECIFICATION Date:

29-JUL-2011

Page: 5 of 48 Equipment such as vessels, exchangers, tanks, drums, fin fan coolers and piping which contain hydrocarbon is considered hazardous. Internal combustion engines, pumps, and compressors are considered nonhazardous. 3.2

Hazardous Area A hazardous area is defined as any area within 30 ft (9.2 m) horizontally and 30 ft (9.2 m) vertically of a potential source of fire. Fire hazardous area for each unit is defined in the Project Fire Hazardous Area Drawings.

3.3

Fire Protection (Fire rating) The hours of protection are defined as the number of hours of exposure to rapid rise fire (UL 1709) while maintaining steel temperature below 1000° F (538° C) unless otherwise specified.

4.0

REQUIREMENTS 4.1

Extent of Fireproofing 4.1.1

Structural Steel 







4.1.2

When supporting fire potential equipment within the battery limits, columns and the beams transmitting the equipment load to the columns shall be fireproofed from their bases to the height of fire potential equipment or 30 feet (9.2 meters) above grade, whichever is greater. Fireproofing in this area shall have a 2-hour, UL 1709 (typical), rating. All bracing carrying vertical loads shall be fireproofed when it is part of a fireproofed supporting system. Bracing used only for wind loading shall not be fireproofed. Platforms, runways, stairways, and their supports shall not be fireproofed The top flange of structural steel beams that support fire potential equipment shall not be fireproofed.

Pipe Racks 



Both the vertical and transverse horizontal members of the first level of pipe racks located within 30 feet (9.2 meters) of fire potential equipment shall be fireproofed. Fireproofing in this area shall have a 2-hour rating. Pipe rack structures more than 30 feet (9.2 meters) from any fire potential equipment normally would not need fireproofing unless unusual conditions of exposure or loading exist. Beams parallel to the pipe shall not be fireproofed. If air cooled exchangers are installed above pipe racks, the upper transverse levels of the pipe racks shall be fireproofed including the full height of the vertical columns. All horizontal structural members supporting air cooled exchangers, including those cantilevered beyond the vertical supports, shall be fireproofed.

THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.



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Page: 6 of 48





4.1.3





Saddles supporting equipment and measuring more than 1 foot (310 mm) in height at their lowest points shall be fireproofed within the fire potential area. Fireproofing in this area shall have a 2-hour rating.



The outside of skirts supporting process vessels shall be fireproofed.



The inside of skirts over 4 feet (1.2 meters) in diameter.



Skirts 4 feet (1.2 meters) and less in diameter shall not be fireproofed on the inside. Skirts which require insulation shall be fireproofed on the uninsulated portions only.

Heaters 



4.1.6

All lugs, brackets, skirts, and legs supporting fire potential equipment located within the fire potential area shall be fireproofed.

Skirts Supporting Fire Potential Equipment



4.1.5

The top flange of pipe bearing beams shall not be fireproofed

Equipment Supports 

4.1.4

Knee braces and tee supports bearing heavy or critical piping shall be fireproofed.

Structural members supporting fired heaters above grade should be fireproofed for heaters handling flammable or combustible liquids. Structural steel members supporting fired heaters in other services should be fireproofed if located within a fire-scenario area. These include fired heaters in other-than hydrocarbon service, such as steam superheaters or catalytic cracking-unit air heaters, if a collapse would result in damage to adjacent hydrocarbon-processing equipment or piping. If structural support is provided by horizontal steel beams beneath the firebox of an elevated heater, fireproofing should be considered for the beams, unless at least one flange face is in continuous contact with the elevated firebox.

Reboilers Supporting lugs and steel supporting reboilers shall be fireproofed. All beams and columns supporting reboilers shall be fireproofed regardless of the elevation of the reboilers.

4.1.7

Electric Power and Instrument Cable Electric, instrument, and control systems used to activate equipment needed to control a fire or mitigate its consequences (such as emergency shutdown systems and isolation valves) should be protected from fire damage, unless they are designed to fail-safe during a fire exposure. If the control wiring used to activate emergency shutdown devices (including depressurization or isolation system) during a fire could be exposed to the fire, the wiring should be protected against a 15 minute fire-exposure functionally




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Page: 7 of 48 equivalent to the conditions of UL 1709. If activation of these emergency systems would not be necessary during any fire to which it might be exposed, then protection of the wire is not required for emergency response purposes. The primary methods of avoiding early cable failure in a fire situation that could prevent the safe shutdown of a plant include the following:

4.1.8

a.

Locate isolation and emergency valves outside fire potential area

b.

Burying cable below grade

c.

Routing cable around areas that have a high fire potential

d.

The use of fireproofed cable trays/conduits

e.

The use of L.V. “Fire Resisting” cables

Pneumatic and Hydraulic Instrument Lines Pneumatic and hydraulic instrument lines shall be protected for the same reason as described in 4.1.7. If Pneumatic and hydraulic instrument lines are from the stainless steel tubing which is highly resistant to failure during a hydrocarbon fire and do not have to be fireproofed with insulating material.

4.1.9

Control Valves The control valves and their activators that should operate during a fire should be protected by various insulating systems that use preformed fire resistant material such as: a.

K-Mass

b.

Lace-up fire resistance blankets

c.

Insulation with stainless steel jacketing

The control valves should be protected against a 15 minute fire-exposure functionally equivalent to the conditions of UL 1709. 5.0

6.0

PAINTING 5.1

Prior to fireproofing, all surfaces shall be coated per the coating specification. Concrete fireproofing shall be applied directly over galvanized steel. For intumescent fireproofing material, manufacturer’s recommendation and requirements in Appendix A or Appendix B shall be followed.

5.2

All studs or clips welded to the steel surface shall be spot cleaned and touch-up primed.

5.3

Prior to fireproofing, all surfaces shall be free of dirt, grease and coating holidays.

MATERIAL 6.1

Concrete or Lightweight Concrete: Form Placed Method and Pneumatically Applied 6.1.1

Concrete for both manual and pneumatic placement shall be mixed in the proportion as determined by the applicator in accordance with Supplier’s recommendation so as to obtain a minimum compressive strength of 2000 psi at 28 days. Water/cement ratio shall




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Page: 8 of 48 not exceed 0.50. Ready-mixed concrete in accordance with ASTM Specification C94 may be used. 6.1.2

Thickness for concrete or lightweight concrete shall be 2 inches (50 mm) minimum.

6.1.3

Portland cement shall be in accordance with ASTM Specification C150.

6.1.4

Aggregate 

Form Placed Method Fine and coarse aggregate shall conform to ASTM Specification C33 for concrete and C330 for lightweight concrete. Maximum aggregate size shall be limited to ½ in (13 mm).



Pneumatically Applied Fine aggregate (sand) shall conform to ASTM Specification C33 for concrete and C330 for lightweight concrete. Maximum aggregate size shall be limited to ¼ in (6.4 mm).



6.2

6.3

Water shall be cold, clean and free of oils, acids, salts or other substances injurious to the concrete. Water of drinkable quality is acceptable

Lightweight Cementitious Products 6.2.1

Commercial lightweight cementitious products are acceptable only when in compliance with the following quality criteria. Ablative coatings, gypsum, and magnesium oxychlorides are not acceptable.

6.2.2

Product must be listed by the Underwriters Laboratories, Inc., for exterior use based upon testing in accordance with UL 1709.

6.2.3

Fireproofing material shall contain no asbestos, toxic, or “red label” solvents.

6.2.4

Fireproofing Supplier shall furnish a list of current installations utilizing the product in question. This list shall contain the locations, type and years of service.

6.2.5

Lightweight products should not be used where structures are susceptible to mechanical abuse (grade to 8 feet (2.44 meters) – use concrete only).

6.2.6

Lightweight cementitious material shall be Pyrocrete 241 as manufactured by Carboline or approved equal.

6.2.7

Thickness for lightweight recommendation.

cementitious

material

shall

the

manufacturer’s

Intumescent Mastic (See Appendix A and B for Material Requirements) 6.3.1

Intumescent mastic material shall consist of a fibrated mastic material in ready mixed form nonflammable when cured, durable under extreme weather conditions and suitable for temperature to 250° F (121 °C). It is a proprietary material.

6.3.2

Thickness for intumescent recommendation.

mastic

fireproofing

shall

be

per

manufacturer’s




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Page: 9 of 48 6.3.3

6.4

Intumescent mastic material shall be from the following manufacturer or approved equal. 

Chartek 1709 - manufactured by International Paint Ltd.



Pitt-Char XP - manufactured by PPG

Reinforcement 6.4.1

Concrete or Lightweight Concrete Fireproofing 



6.4.2



7.0

2

2

Metal lath shall be 3.4 lb/yd (1.84 kg/mg ) galvanized diamond metal lath.

Intumescent Mastic Fireproofing 

6.5

Annealed stainless steel wire shall be used for tie wire mesh where necessary.

Lightweight Cementitious Fireproofing 

6.4.3

Welded wire mesh shall be 2 in x 2 in (50 mm x 50 mm), 12/12 gauge.

Reinforcement for Chartek 1709 – HK-1 (M) composite mesh).

(hybrid carbon and glass

Reinforcement for Pitt-Char XP – Galvanized Steel Hardware Cloth ½” x ½” x 19 gage

Waterproof Mastic 6.5.1

Waterproof Mastic shall be Pecora Silicone No. 864 or approved equal.

6.5.2

Primer shall be P-65 or approved equal.

INSTALLATION 7.1

Concrete Fireproofing 7.1.1

Concrete fireproofing shall be used for equipment supports (skirts, saddles, and legs). Over light weight concrete, 8 ft of steel column from grade level, shall have two inch (50 mm) minimum thickness pneumatically applied or poured in place concrete. 







7.1.2

The concrete shall be held in place by wire mesh as defined below. Fireproofing need not be rubbed to a smooth finish, provided there is no honeycombing. Fireproofing shall have the equivalent of a wood float finish. Any cracks wider than 1/16 in. (1.5 mm) shall be repair ed.

Wire mesh shall be secured to studs or clips welded to the steel structure approximately 18 in. (450 mm) apart and shall be fastened approximately ¾ in. (19 mm) from the surface of the steel work. Clips and studs shall not be longer than 1 in. (25 mm). 

A 3 in. (75 mm) minimum lap shall be used for j oining wire mesh.




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Page: 10 of 48



Seller shall add crimp rods on beams and columns as required to support reinforcement for fireproofing materials.

7.1.3

Any unusual details such as reboiler supports necessary for applying fireproofing to structural steel members shall be shown on the structural steel drawings.

7.1.4

All exposed concrete corners shall be chamfered or rounded. Top surfaces shall be sloped for drainage. Exposed joints between steel and concrete shall be sealed with waterproof mastic equal to Pecora Silicone No. 864 with the Pecora P-65 primer.

7.1.5

7.2

7.3

All joints between fireproofing and steel shall be chipped or tooled and filled with a sealing compound, Thiokol base sealant, Pecora sealant or authorized equal to prevent the intrusion of moisture.

Lightweight Cementitious Fireproofing 7.2.1

Fireproofing of structural steel shall be with either concrete or lightweight cementitious material. Thickness of the concrete shall be 2 in. (50 mm) minimum. Thickness of the special material shall be per manufacturer’s recommendation.

7.2.2

When fireproofing is required for structural elements, all sides of the steel shape shall be covered except the top flange of beams which support process equipment, flooring, piping, etc.

7.2.3

Concrete fireproofing on all sides of beams and columns shall be applied in accordance with Paragraph 7.1 of this specification.

7.2.4

Lightweight fireproofing material shall be held in place by 3.4 lb/yd galvanized diamond metal lath.

7.2.5

A final surface resembling a wood float finish shall be considered satisfactory.

7.2.6

For columns and beams of contour design, naturally rounded off corners of proper thickness are acceptable.

7.2.7

On columns and beams boxed design construction shall not be used.

7.2.8

Caulking and sealing shall be done with product listed in Section 7.1.4 and 7.1.5.

2

Intumescent Mastic Fireproofing (See Appendix A and B for Application Requirements) 7.3.1

Intumescent Mastic fireproofing shall be used only where required and shall be identified by the Owner.

7.3.2

Intumescent Mastic fireproofing shall be recommendation by certified applicator only.

7.3.3

Manufacturer’s representative should be present at beginning of application and follow up.

7.3.4

Surface preparation and primer coat shall be per manufacturer’s recommendation.

7.3.5

Top coat shall be applied as per manufacturer’s recommendation.

installed

as

per

manufacturer’s




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Page: 11 of 48 8.0

WORKMANSHIP 8.1

8.2

Preparation 8.1.1

Overspraying on adjacent piping, equipment, instruments, aluminium metal surfaces, etc. Is not acceptable. Seller shall protect all adjacent areas either by shielding by masking or covering with plastic tarps. Seller shall be responsible for removing all overspray fireproofing materials.

8.1.2

Fireproofing shall not be installed when temperature is below 40°F (5°C) or expected to be below 40°F (5°C) in next 24 hours. Seller shall provide suitable means of heating the newly installed fireproofing to a minimum of 40°F (5°C) for at least 24 hours after placing. Substrate temperatures shall always be above 40°F (5°C) when fireproofing is being applied.

8.1.3

Fireproofing shall not be installed during periods of high winds or rain.

8.1.4

Spot prime areas to be fireproofed where the shop preparation is damaged.

8.1.5

Steel members to receive fireproofing shall be cleaned, dried and made free of oil, dirt, and other foreign material.

Curing 8.2.1

Fireproofing material shall be cured per Manufacturer’s recommendation and shall be wetted as required to allow full curing.

8.2.2

Polyethylene film or wet burlap shall be used to retain moisture in curing of fireproofing material.

ATTACHMENTS




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ATTACHMENT I FIREPROOFING STEEL STRUCTURES




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ATTACHMENT II STRUCTURAL STEEL PIPE AND EQUIPMENT SUPPORT




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ATTACHMENT III FIREPROOFING DETAILS USING CONCRETE MATERIAL

4.

WELDED WIRE MESH SHALL BE USED IN LIEU OF HEXAGONAL POULTRY MESH AS STATED IN NOTE 3 ABOVE.




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ATTACHMENT IV FIREPROOFING DETAILS USING SPECIAL MATERIALS




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ATTACHMENT V FIREPROOFING DETAILS FOR VESSEL SKIRTS




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APPENDIX A – APPLICATION OF INTUMESCENT FIREPROOFING USING CHARTEK 1709 1.0

Scope This appendix covers requirements for material and application of intumescent fireproofing.

2.0

1.1

Blockout areas for field connection including bolt holes shall not be fireproofed in the shop but shall receive surface preparation and primer coat per this specification.

1.2

Blockout areas shall be kept to minimum. See structural steel drawings for the blockout details.

1.3

Installation details are shown in ATTACHMENT E

1.4

Top face of flange and top edges on beams supporting pipe and equipment shall not be fireproofed. The entire beam shall be blast cleaned per Section 7.2 and primed with Intergard 251 per Section 8.3. Top face including the edges shall be masked off during fireproofing application. All surfaces except top face and top edges shall be fireproofed with Chartek 1709 per this specification. The top face and edges (Non-fireproofed surface) shall receive one coat of Interzone 954, 10 mils (250 mcrons) MDFT and top coat of Interthane 990, 2 to 3 mils (50 to 75 microns) MDFT, Interzone 954 and Interthane 990 shall be applied after Chartek application.

1.5

All horizontal finished surface of fireproofing such as column base plate, top face of bottom 0 flange on beams, etc. shall have 5 slope to prevent water ponding.

1.6

Fireproofing zone of galvanized columns shall be sweep blasted per Section 7.3 and primed with Intergard 251 primer per Section 8.3 prior to application of Chartek 1709.

1.7

Galvanized bolt on bolted connection shall be solvent wiped and surface shall be abraded with 80 grit sand paper, dust removed prior to application of Intergard 251 primerand finish off with Chartek 1709 and Interthane 990. This application can be combined with fireproofing of field block outs.

Applicator’s Responsibility Applicator QA/QC responsibiliti es as follows a.

Supply the equipment for the specified inspections and tests required for fireproofing activities.

b.

Supply new and undamaged fireproofing materials received at the shop or field jobsite in the manufacturer’s original sealed containers.

c.

Proper storage of all materials in the area protected from weather before and during application

d.

Inspection of fireproofing materials and accessories prior to commencement of work. Any material that has been damaged or found to be defective shall be removed and replaced by the seller at his expense.

e.

Inspection during key construction phase include, proper storage of materials, surface preparation, primer application, equipment setup and application (Chartek 1709), Installation of reinforcing mesh (HK-1 M), Chartek 1709 thickness measurements and topcoat application

f.

Applicator / Steel fabricator shall ensure that the applicator conforms to QC MAN GB, Rev.4. This includes (Samples attached to this specification ) Chartek Fireproofing - Area Quality Control Report Chartek Fireproofing Daily Log




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Page: 18 of 48 Chartek Fireproofing Equipment Quality Control Report 3.0

Manufacturer Responsibility A technical service audit shall be conducted by the manufacturer during the initial start of fireproofing and provide technical assistance during production phase.

4.0

Submittals a.

Applicator shall submit to the buyer a list of materials to be used in fireproofing and shall identify the specific design mix including manufacturer’s datasheets and MSDS sheets.

b.

Applicator shall submit written procedures for storage, handling, surface preparation, environmental control, application, verification of fireproofing thickness, repair, and inspection of the fireproofing. Procedures shall be submitted to Purchaser for review and approval prior to using them.

c.

Subcontractor shall submit to Purchaser for review fireproofing verification forms as specified in clause 2..0 (f). Daily inspection forms shall be accessible for spot review on a daily basis.

d.

Fireproofing verification forms shall be used to verify that proper materials were used, and that accepted application procedures and specifications were followed. Fireproofing verification forms shall include a statement of completion conformance.

5.0

Materials

1.

General Fireproofing materials shall conform to C1709 APP MAN UK, Rev. 0 5.2

Primer a. Primer shall be International Intergard 251 b. Mid coat for top face of flange on beam Interzone 954 c.

5.3

Primer shall be approved and UL 1709 tested.

Chartek 1709 1.

Fireproofing shall be CHARTEK 1709 manufactured by International Protective Coating/Akzo Nobel.

2.

CHARTEK 1709 shall meet the requirements of UL1709, per XR design rating.

3.

Fire rating of CHARTEK 1709 shall be 2 hour per UL1709 in accordance with CHARTEK 1709 Design XR625

4.

CHARTEK 1709 shall have the following minimum physical properties: a. Dry density –62 lb/ft3 b.

Compressive strength – 1,500 psi (determined in accordance with ASTM D695)

c.

Hardness – Shore D 55-65 (determined in accordance with ASTM D2240)

d.

Flexural strength – 36,250 psi (determined in accordance with ASTM D790)

e.

Flame spread – Class A 25 (determined in accordance with ASTM E84)




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5. 5.4

5.5

f.

Smoke developed – Class A 300 (determined in accordance with ASTM E84)

g.

Adhesion strength to steel – 1450 psi (determined in accordance with ASTM D4541)

Testing shall be performed to determine physical properties for above items a, b, c, d, and g.

Reinforcing Mesh 1.

Reinforcing mesh shall be HK-1 (M) (hybrid carbon and glass composite mesh).

2.

Reinforcing mesh shall be supplied by the mastic manufacturer.

Topcoat 1.

Topcoat shall be international Interthane 990 or as specified by the mastic manufacturer. .

2. Finish color shall be Medium Gray per RAL 7004. 6.0

Preconstruction Activities 6.1

Preconstruction Meeting 1.

Project Engineer shall arrange for a preconstruction meeting with the following individuals in attendance: a. Purchaser Project Engineer (primary project contact) b. Purchaser Non Metallic Technologist c. Purchaser Lead Civil Engineer d. Purchaser QA/QC Inspector e. Subcontractor representatives, including QC coordinator and foreman assigned to the job f. Contractor structural steel fabrication/erection representative g. Manufacturer representative

2. Agenda to be covered at the preconstruction meeting shall include the followi ng: a. Review of Contractor’s submittals and this specification b. Inspection hold points c. Controls of environmental conditions in the shop d.

Condition of steel necessary to accept fireproofing

e.

Surface preparation and compatible primer application

f.

Fireproofing application, installation of reinforcement, and thickness measurements

g.

Cure measurement prior to application of topcoat

h.

Proper topcoat application




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Exposure to elements only after system is completely sealed

Sample Preparation and Adhesion Testing 1.

Applicator shall prepare a fireproofing sample on a 6 ft. long W10x49 carbon steel beam. The sample shall have pockets and tabs to represent complex shape.

2.

Sample requires inspection and approval in writing by the Purchaser before the Applicator proceeds with application of the fireproofing.

3.

Sample shall illustrate correct fireproofing appearance, thickness, reinforcing, and surface finish, and shall be used as the application standard.

4.

Sample shall be tested for adhesion in accordance with ASTM D4541. a. Adhesion of primer to steel or galvanizing shall be a minimum of 300 psi. b. Adhesion of fireproofing to primer shall be a minimum of 300 psi. c. Adhesion of topcoat to fireproofing shall be a minimum of 300 psi.

6.3

5.

Owner or his representative, Contractor, Subcontractor, and Manufacturer shall approve the sample.

6.

Two random production pieces that are shop fireproofed shall also be tested for adhesion.

Area Inspection Area that will receive fireproofing shall be inspected to verify that ducts, piping, equipment, or other items that would interfere with application of fireproofing are not positioned until fireproofing work is complete.

7.

Substrate Inspection and Preparation 7.1

7.2

7.3

Inspection 1.

Substrate shall be inspected to verify that it is ready to be cleaned/blasted.

2.

Substrate shall be uniform and free of defects, such as weld deficiencies, lack of seal welding, and poor drainage of galvanizing.

3.

Any substrate defects that may adversely affect adhesion or performance of the fireproofing shall be properly repaired.

Non-Galvanized Substrate 1.

Non-galvanized substrate shall be blasted in accordance with SSPC SP-10.

2.

Blasted substrate shall have an anchor pattern of 2.0 to 3.0 mils minimum.

3.

Specific abrasive shall be determined by the Applicator and approved by the Manufacturer prior to use.

Galvanized Substrate 1.

Galvanized substrate shall be cleaned and degreased in accordance with SSPC SP-1. Alkaline cleaners shall not be used.




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8.

2.

Cleaned substrate shall be blasted in accordance with SSPC SP-7/NACE No. 4. Abrasive shall conform to SSPC AB-1.

3.

Blasted substrate shall have an anchor pattern that is sharp with no evidence of a polished surface.

Fireproofing Application 8.1

Ambient Considerations 1. Fireproofing shall be applied when:

2.

a.

Substrate temperature and ambient temperature are on the rise and greater than 50°F.

b.

Ambient temperature is 5°F above the dew point.

c.

Relative humidity is less than 85%.

Areas where fireproofing is applied shall be ventilated for 24 hours after application.

3. Work area shall be kept clean and well ventilated. 4. 8.2

8.3

8.4

Spillage and over-spray shall be removed promptly before material has cured.

Protection of Adjacent Areas 1.

Adjacent equipment and surfaces that will not be fireproofed shall be protected from damage by over-spray, fall-out, or dusting.

2.

Ducts in areas where fireproofing is being applied shall be closed and sealed.

Primer Application 1.

Primer shall be applied to a dry film thickness (DFT) of 2 to 3 mils. Maximum allowable DFT on overlaps shall be 3 mils.

2.

For non-galvanized substrate, primer shall completely cover the blast profile.

3.

Prior to application of primer, on galvanized substrate, excessive zinc thickness may be reduced by sanding with P80-P-100 grade aluminum oxide abrasive paper for small areas. Polishing shall be avoided. For large surfaces, galvanized surface shall be sweep blasted per SSPC-SP7

CHARTEK 1709 Mixing 1.

Properly mixed CHARTEK 1709 is light gray (with no striping).

2.

A quality control check for mixing shall be a ratio check, performed by the Subcontractor. The ratio check shall be by weight as follows: a.

Weigh clean empty Parts A and B containers and note the respective weight.

b.

Place the container under the ratio check valves located on the mixing block and open the valve at exactly the same time.

c.

Close the valves when the containers are at least half full at exactly the same time.

d.

Calculate the ratio of Part A and Part B as a percentage of the total weight. Example Part A to Part B ratio is 2.5:1.




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Page: 22 of 48 3. 8.5

8.6

A minimum of two ratio checks shall be performed per shift, (1) start of the shift and (2) when the pump is shut down and restarted.

CHARTEK 1709 Application 1.

Primer shall be allowed to cure for a minimum of twelve hours at 77°F before the CHARTEK 1709 is applied.

2.

Before CHARTEK 1709 is applied, primed substrate shall be cleaned of dirt, dust, grease, oil, loose material, or other matter that may adversely affect CHARTEK 1709 bond.

3.

CHARTEK 1709 shall be applied in accordance with APP MAN C1709, Rev 0.

4.

CHARTEK 1709 materials shall be kept within a temperature range of 86˚F to 93˚ F for 24 hours prior to use.

5.

CHARTEK 1709 shall be applied using plural component spray equipment. suppliers recommended by the Manufacturer are as follows:

Equipment

a.

Spray-Quip, Inc., 1754 Des Jardines, Houston, TX 77023 – Herb Chilman, Sr., 800-5009109

b.

Airtech Spray Systems, Inc., 4303 Pinemont, Houston, TX 77018 – Joe Acosta, 713681-0013

6.

Operating parameters for plural component spray equipment shall be in accordance with APP MAN C1709, Rev 1.

7.

CHARTEK 1709 shall be applied to a minimum thickness of 10.7 mm per BYBU. XR 625 for 2 hour rating (UL 1709 certification directory). a.

Minimum thickness at any one point shall not be less than 85% of specified thickness.

b.

Overall average thickness shall be equal to, or greater than, the UL specified thickness.

c.

UL certified thickness is based on the average thickness.

Reinforcing Mesh Application 1.

Reinforcing mesh shall be cut to required size before CHARTEK 1709 is applied.

2.

Mesh shall be rolled thoroughly into the wet CHARTEK with short nap roller lightly dampened with International PMA solution.

3.

Adjacent pieces of mesh shall be overlapped by a minimum of 2 in.

4.

Mesh shall be placed at approximately mid thickness of the CHARTEK 1709.

5. Mesh shall be applied over flanges as shown on the details. 6. Mesh also shall be installed over web if web span is greater than 10 inches or as required per manufacturer’s application procedure. 8.7

Topcoat Application 1.

Topcoat of Interthane 990 shall be applied in accordance with APP MAN C1709, Rev 0.

2.

Unless otherwise specified, topcoat shall be applied within seven days after the CHARTEK 1709 is applied. If the seven days are exceeded, the surface of the CHARTEK 1709 shall be




29-JUL-2011

Page: 23 of 48 sweep blasted or mechanically abraded with 40 grit paper (or equivalent) and solvent cleaned prior to applying the topcoat. 3. Topcoat shall be applied to a minimum DFT of 2 to 3 mils. 9.

Inspection, Testing, and Repair 9.1

Daily Production Samples and Tests 1.

2.

9.2

Daily production samples shall be taken one per shift. Additional samples shall be taken if material batch numbers change. This can be accomplished by spraying material into a plastic cup and identifying sample number and date. a.

Samples shall be tested randomly to determine fireproofing hardness and density properties.

b.

Sample shall be documented on the CHARTEK Fireproofing Daily Log.

The following inspections and tests shall be performed on a daily basis. a.

Degreasing stage – surface contamination – Visual, white cloth check for oils or other harmful contaminates [SOVENT WIPE TEST]

b.

Blast cleaning – Visual inspection to ensure sheen surfaces are dulled by sweep blasting steel [VISUAL]

c.

Primer – Wet film thickness measurements primer [WET FILM GAGE]

d.

Inspect spray equipment – Operating conditions of plural component equipment [MATERIAL RATIO WEIGHT CHECK]

e.

Application of CHARTEK 1709 – Inspect wet film thickness with approved [WET FILM GAGE Internationals Thickness Gauge ], observe mesh installation

f.

CHARTEK 1709 dry film thickness test [approved electronic meter Ecometer Model 456 or 355 with either F3 or F6 probe]

g.

Inspect cure of CHARTEK 1709 – [DUROMETER SHORE D]

h.

Topcoat – Inspect application of topcoat [WET FILM THICKNESS]

i.

Environmental test equipment – Sling pychrometer, surface thermometer

Deficiency Inspection and Repair 1.

2.

Deficiencies in the fireproofing shall be inspected, noted, and properly repaired. Deficiencies include, but are not limited to, the following: a.

Cracks of any length in CHARTEK 1709.

b.

Disbondment of primer, CHARTEK 1709, or topcoat

c.

Exposed reinforcing mesh

d.

Inadequate fireproofing thickness.

e.

Excessive mills and subsequent coating runs, drips, spills, and curtains.

Repair of deficiencies shall conform to Section 10.0 of APP MAN C1709, Rev 0. necessary, Manufacturer shall write repair procedures not covered in APP MAN C1709.

If




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Page: 24 of 48 3. 9.3

A written repair procedure shall be submitted to the Purchaser before repairs are performed.

Hardness Test 1.

CHARTEK 1709 shall be given a Shore D Hardness test 48 hours after CHARTEK application and before application of the topcoat.

2.

Shore D Hardness test shall be performed using a Durometer gauge.

3. CHARTEK 1709 shall have a minimum hardness of 40 Shore D.

9.4

4.

Hardness readings shall be taken on areas that are relatively smooth.

5.

Ten readings shall be taken per area, discarding the low and high reading.

Density Test 1.

Random daily production samples (see 8.1) of CHARTEK 1709 shall be tested for density a minimum of once per week. 3

2. CHARTEK 1709 shall have a minimum density of 62 lbs./ft . 9.5

Final Inspection Final inspection of the installed fireproofing shall be performed jointly by the Applicator and the Purchaser.

9.6

Test Results Test results shall be recorded on “CHARTEK Fireproofing –Area Quality Control Report” and the “Fireproofing Daily log”.

10.

Curing Fireproofed surfaces shall not be exposed to the exterior elements until the fireproofing is completely cured and the topcoat is properly sealed over the entire fireproofed surface.

11.

Shipping and Handling All fireproofed steel shall be handled using nylon slings or other approved lifting methods. Proper dunnage during transport, storage and jobsite erection shall be used to minimize damage to the fireproofing.




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ATTACHMENT A – CHARTEK® FIREPROOFING – AREA QUALITY CONTROL REPORT

Project:

Owner:

Owner’s representative:

Applicator’s representative:

Area identification: see attached drawing Report Nº: XXX – A OPERATION

Date: DATE

Nº TEST ACTIVITY (see QCP nº XXX)

Prepared by: SIGNATURE SITE MANAGER/QC

COMMENTS

BLAST CLEANING-PRIMER-MASKING Blast cleaningprimer Acceptance of surfaces Masking Sample area CHARTEK APPLICATION-MESHING 1st Coat Mesh installation 2nd Coat TOPCOAT 1st Coat 2nd Coat NOTES

AREA COMPLETE

Applicator:

Signature:

Name:

Owner:

Signature:

Name:




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ATTACHMENT B-CHARTEK® FIREPROOFING DAILY LOG PERSONNEL Project:

Owner:



Area identification: see attached drawing Report Nº: XXX - B Date: Site Manager:

Prepared by:

Site QA/QC Manager: Sprayers-trowellers: Owner’s QC Inspector: ENVIRONMENTAL CONDITIONS (to be recorded every hour) Time Ambient temp. Relative humidity Dew point Substrate temp. MESH INSTALLATION Mesh installed (type and surface area in m2): Edge mesh (Charlok) installed (linear meters): Part A

CHARTEK STORAGE TEMPERATURE

Part B

CHARTEK APPLICATION Ratio (% in weight)

A.M. Part A

Part B

P.M. Part A Part B

SPRAY EQUIPMENT ID (type and serial number): ID areas coated (if different from drawing) Specified thickness (mm) Thickness applied to date Thickness applied today Surface area coated (m2 ) Chartek quantity used (no. of kits) Part A Part B

Solvent used : Type Quantity (lt.)

CHARTEK BATCH NUMBERS Part A: Part B: NOTES Signature Site Manager-Site QA/QC Manager:




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ATTACHMENT C- CHARTEK® FIREPROOFING EQUIPMENT QUALITY CONTROL REPORT

Project:

Owner:



Area identification: see attached drawing Report Nº: XXX – C

Date:

Prepared by:

PLURAL COMPONENT SYSTEM Machine type

Hose length Preloading Chartek temperature

Part A:

Part B:

Tank temperatures

Part A:

Part B:

Tank pressures

Part A:

Part B:

In-line heater temperatures

Part A:

Part B:

Displacement pump pressures (at cylinder exit)

Part A:

Part B:

Tip size (1/1000”):

Fan size (mm):

Line heat Gun exit temperature Spray gun NOTES

Signature Site Manager-Site QA/QC Manager:




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ATTACHMENT D – UL Certification of Chartek 1709

Fire Resistance Ratings - ANSI/UL 1709 See General Information for Fire Resistance Ratings -ANSI/UL 1709 Design No. XR625

October 09, 2006 Ratings - 1/2, 3/4, 1, 1-1/2, 2, 2-1/2, 3, 3-1/2 Hr. (See Item 3)

1 2

Steel Column — Min. size W10X49. The column surfaces shall be free of dirt, loose scale and oil then primed with epoxy based primers to an approximate dry film thickness of 2 mils. Flange Edge Reinforcement — Carbon fiberglass mesh Type HK-1 applied over the flange tips at approximately mid-depth of the total thickness of mastic coating.




29-JUL-2011

Page: 29 of 48 3.

Mastic Coating — Two component spray materials applied in one or more coats as described in the application instructions to the thickness shown below. Thickness below includes 2 mils (50 micron) of primer.

Material Thickness, Microns

Material Thickness, Microns

With Mesh (Item 2)

Without Mesh (Item 2)

Rating, Hr 1/2

-

2740

3/4

-

4550

1

-

5780

1-1/2

8240

-

2

10700

-

2-1/2

13160

-

3

15620

-

3-1/2

18080

-

INTERNATIONAL PAINT LTD — Type Chartek 1709. Investigated for exterior use.

4. Top Coat — One of the following topcoats shall be used. Two component polyurethane topcoat Type Interthane 990 applied at a dry film thickness of 50 microns. Two component polyurethane topcoat Type Interthane 990HS applied at a dry film thickness of 50 microns. Two component polysiloxane topcoat Type Interfine 878 applied at a dry film thickness of 50 microns. Two component polysiloxane topcoat Type Interfine 979 applied at a dry film thickness of 100 microns. *Bearing the UL Classification Mark Last Updated on 2006-10-09 Copyright © 2007 Underwriters Laboratories Inc. ® The appearance of a company's name or product in this database does not in itself assure that products so identified have been manufactured under UL's Follow-Up Service. Only those products bearing the UL Mark should be considered to be Listed and covered under UL's Follow-Up Service. Always look for the Mark on the product. UL permits the reproduction of the material contained in the Online Certification Directory subject to the following conditions: 1. The Guide Information, Designs and/or Listings (files) must be presented in their entirety and in a non-misleading manner, without any manipulation of the data (or drawings). 2. The statement "Reprinted from the Online Certifications Directory with permission from Underwriters Laboratories Inc." must appear adjacent to the extracted material. In addition, the reprinted material must include a copyright notice in the following format: "Copyright © 2007 Underwriters Laboratories Inc.®"




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ATTACHMENT E – Installation Details




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ATTACHMENT E – Installation Details (Continue)




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ATTACHMENT E – Installation Details (Continue)

Note:

HK-1 (M) Mesh is required on web if web dimension is greater than 10 inches (250 mm) and as required per Chartek 1709 Application Manual.




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APPENDIX B – APPLICATION OF INTUMESCENT FIREPROOFING USING PITT-CHAR XP 1.0

Scope This appendix covers requirements for material and application of intumescent fireproofing.

2.0

1.1

Blockout areas for field connection including bolt holes shall not be fireproofed in the shop but shall receive surface preparation and primer coat per this specification.

1.2

Blockout areas shall be kept to minimum. See structural steel drawings for the blockout details.

1.3

Installation details are shown in ATTACHMENT E.

1.4

Top face of flange and top edges on beams supporting pipe and equipment shall not be fireproofed. The entire beam shall be blast cleaned per Section 7.2 and primed with SigmaCover 280 per Section 8.3. Top face including the edges shall be masked off during fireproofing application. All surfaces except top face and top edges shall be fireproofed with Pitt-Char XP per this specification. The top face and edges (Non-fireproofed surface) shall receive one coat of Amerlock 400 GF, 8-12 mils (200-300 mcrons) MDFT and top coat of ei ther Sigmadur 550 (gray) or Amercoat 450H, 2 to 3 mils (50 to 75 microns) MDFT. These coatings shall be applied after Pitt-Char XP application.

1.5

All horizontal finished surface of fireproofing such as column base plate, top face of bottom 0 flange on beams, etc. shall have 5 slope to prevent water ponding.

1.6

Fireproofing zone of galvanized columns shall be sweep blasted per Section 7.3 and primed with SigmaCover 280 per Section 8.3 prior to application of Pitt-Char XP.

1.7

Galvanized bolt on bolted connection shall be solvent wiped and surface shall be abraded with 80 grit sand paper, dust removed prior to application of SigmaCover 280 primer and finish off with Pitt-Char XP and approved top coat system. This application can be combined with fireproofing of field block outs.

Applicator’s Responsibility Applicator QA/QC responsibiliti es as follows a.

Supply the equipment for the specified inspections and tests required for fireproofing activities.

b.

Supply new and undamaged fireproofing materials received at the shop or field jobsite in the manufacturer’s original sealed containers.

c.

Proper storage of all materials in the area protected from weather before and during application

d.

Inspection of fireproofing materials and accessories prior to commencement of work. Any material that has been damaged or found to be defective shall be removed and replaced by the seller at his expense.

e.

Inspection during key construction phase include, proper storage of materials, surface preparation, primer application, equipment setup and application (Pitt-Char XP), Installation of reinforcing mesh (Galvanized Steel), Pitt-Char XP thickness measurements and topcoat application.

f.

Applicator shall ensure that the applicator conforms to latest QC Manual. This included (sample attached to this specification) Pitt-Char XP

Customer / Applicator Area QC Report




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3.0

Pitt-Char XP

Reference Smple

Pitt-Char XP

Plural Equipment Daily Report

Pitt-Char XP

Daily Log

Manufacturer Responsibility A technical service audit shall be conducted by the manufacturer during the initial start of fireproofing and provide technical assistance during production phase.

4.0

5.0

Submittals 4.1

Applicator shall submit to the buyer a list of materials to be used in fireproofing and shall identify the specific design mix including manufacturer’s datasheets and MSDS sheets.

4.2

Applicator shall submit written procedures for storage, handling, surface preparation, environmental control, application, verification of fireproofing thickness, repair, and inspection of the fireproofing. Procedures shall be submitted to Purchaser for review and approval prior to using them.

4.3

Subcontractor shall submit to Purchaser for review fireproofing verification forms as specified in clause 2.0 (f). Daily inspection forms shall be accessible for spot review on a daily basis.

4.4

Fireproofing verification forms shall be used to verify that proper materials were used, and that accepted application procedures and specifications were followed. Fireproofing verification forms shall include a statement of completion conformance.

Materials 5.1

General Fireproofing materials shall conform to PPG Industries Pitt-Char XP Application Manual.

5.2

Primer a. Primer shall be PPG SigmaCover 280. b. Mid coat for top face of flange on beam PPG Amerlock 400GF c.

5.3

Primer shall be approved and UL 1709 tested.

Pitt-Char XP

5.2 5.3 5.3.1

Fireproofing shall be Pitt-Char XP manufactured by PPG Industries Inc.

5.3.2

Pitt-Char XP shall meet the requirements of UL1709, per XR 612.

5.3.3

Fire rating of Pitt-Char XP shall be 2 hour per UL1709 in accordance with Pitt-Char XP Design XR 612

5.3.4

Pitt-Char XP shall have the following minimum physical properties: 3

a. Dry density – 68 lb/ft b.

Compressive strength – 2264 psi (determined in accordance with ASTM D695)




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Page: 35 of 48 c.

Hardness – Shore D 35 when fully cured (determined in accordance with ASTM D2240)

d.

Flame spread – Class A 15 (determined in accordance with ASTM E84)

e.

Smoke developed – Class A 70-110 (determined in accordance with ASTM E84)

f.

Impact Strength – 1.46 ft. lbs/in (determined in accordance with ASTM D265 “A”)

g.

Adhesion strength to steel – 750 psi (determined in accordance with ISO 4624 for film thickness <2mm, unreinforced))

Testing shall be performed to determine physical properties for above items a, b, c, f, and g. 1. 2. 3. 4. 5. 5.4

5.5

Reinforcing Mesh 1.

Reinforcing mesh shall be galvanized steel hardware cloth ½” x ½” x 19 gage.

2.

Reinforcing mesh shall be obtained locally or as required by applicator.

Topcoat 1.

Topcoat shall be Sigmadur 550 (gray) or Amercoat 450H at 2-3 mils DFT.

2. Finish color shall be Medium Gray per RAL 7004. 6.0

Preconstruction Activities 6.1

Preconstruction Meeting 6.1.1

Project Engineer shall arrange for a preconstruction meeting with the following individuals in attendance: a.

Purchaser Project Engineer (primary project contact)

b.

Purchaser Non Metallic Technologist

c.

Purchaser Lead Civil Engineer

d. Purchaser QA/QC Inspector e.

Subcontractor representatives, including QC coordinator and foreman assigned to the job

f.

Contractor structural steel fabrication/erection representative

g. Manufacturer representative 6.1.2

Agenda to be covered at the preconstruction meeting shall include the following: a.

Review of Contractor’s submittals and this specification




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Page: 36 of 48 b. Inspection hold points

6.2

c.

Controls of environmental conditions in the shop

d.

Condition of steel necessary to accept fireproofing

e.

Surface preparation and compatible primer application

f.

Fireproofing application, installation of reinforcement, and thickness measurements

g.

Cure measurement prior to application of topcoat

h.

Proper topcoat application

i.

Exposure to elements only after system is completely sealed

Sample Preparation and Adhesion Testing 1.

Applicator shall prepare a fireproofing sample on a 6 ft. long W10x49 carbon steel beam and two 6” x 6” x ¼” minimum carbon steel plates. The sample shall have pockets and tabs to represent complex shape. All samples shall be blasted, primed and top coated per project specification.

2.

Sample requires inspection and approval in writing by the Purchaser before the Applicator proceeds with application of the fireproofing.

3.

Sample shall illustrate correct fireproofing appearance, thickness, reinforcing, and surface finish, and shall be used as the application standard.

4.

Carbon steel plate samples minimum 6” x 6” x ¼” shall be tested for adhesion in accordance with D4541 on unreinforced Pitt-Char XP only. Plates shall have surface preparation similar to beam with Pitt-Char XP applied to a maximum thickness of 2mm. a. Adhesion of primer to steel or galvanizing shall be a minimum of 300 psi. b. Adhesion of fireproofing to primer shall be a minimum of 300 psi. c. Adhesion of topcoat to fireproofing shall be a minimum of 300 psi.

6.3

5.

Owner or his representative, Contractor, Subcontractor, and Manufacturer shall approve the sample.

6.

Two random production pieces that are shop fireproofed shall also be tested for adhesion.

Area Inspection Area that will receive fireproofing shall be inspected to verify that ducts, piping, equipment, or other items that would interfere with application of fireproofing are not positioned until fireproofing work is complete.

7.

Substrate Inspection and Preparation 7.1

Inspection 1.

Substrate shall be inspected to verify that it is ready to be cleaned/blasted.

2.

Substrate shall be uniform and free of defects, such as weld deficiencies, lack of seal welding, and poor drainage of galvanizing.




29-JUL-2011

Page: 37 of 48 3. 7.2

7.3

8.

Any substrate defects that may adversely affect adhesion or performance of the fireproofing shall be properly repaired.

Non-Galvanized Substrate 1.

Non-galvanized substrate shall be blasted in accordance with SSPC SP-10.

2.

Blasted substrate shall have an anchor pattern of 2.0 to 3.0 mils minimum.

3.

Specific abrasive shall be determined by the Applicator and approved by the Manufacturer prior to use.

Galvanized Substrate 1.

Galvanized substrate shall be cleaned and degreased in accordance with SSPC SP-1. Alkaline cleaners shall not be used.

2.

Cleaned substrate shall be blasted in accordance with SSPC SP-7/NACE No. 4. Abrasive shall conform to SSPC AB-1.

3.

Blasted substrate shall have an anchor pattern that is sharp with no evidence of a polished surface.

Fireproofing Application 8.1

Ambient Considerations 1. Fireproofing shall be applied when:

2.

a.

Substrate temperature and ambient temperature are on the rise and greater than 50°F.

b.

Ambient temperature is 5°F above the dew point.

c.

Relative humidity is less than 85%.

Areas where fireproofing is applied shall be ventilated for 24 hours after application.

3. Work area shall be kept clean and well ventilated. 4. 8.2

8.3

Spillage and over-spray shall be removed promptly before material has cured.

Protection of Adjacent Areas 1.

Adjacent equipment and surfaces that will not be fireproofed shall be protected from damage by over-spray, fall-out, or dusting.

2.

Ducts in areas where fireproofing is being applied shall be closed and sealed.

Primer Application 1.

Primer shall be applied to a dry film thickness (DFT) of 2 to 3 mils. Maximum allowable DFT on overlaps shall be 3 mils.

2.

For non-galvanized substrate, primer shall completely cover the blast profile.

3.

Prior to application of primer, on galvanized substrate, excessive zinc thickness may be reduced by sanding with P80-P-100 grade aluminum oxide abrasive paper for small areas.




29-JUL-2011

Page: 38 of 48 Polishing shall be avoided. For large surfaces, galvanized surface shall be sweep blasted per SSPC-SP7 8.4

PITT-CHAR XP Mixing 1.

Properly mixed PITT-CHAR XP is a medium gray (with no striping).

2.

A quality control check for mixing shall be a ratio check, performed by the Subcontractor. The ratio check shall be by weight as follows:

3. 8.5

a.

Weigh clean empty Parts A and B containers and note the respective weight.

b.

Place the container under the ratio check valves located on the mixing block and open the valve at exactly the same time under 2000 psi pump pressure or as required to give a slow steady flow.

c.

Close the valves when the containers are at least half full at exactly the same time.

d.

Calculate the ratio of Part A and Part B as a percentage of the total weight. Example Part A to Part B ratio is 3.25:1. Acceptable range is from 2.93 to 3.58:1.

A minimum of two ratio checks shall be performed per shift, (1) start of the shift and (2) when the pump is shut down and restarted.

PITT-CHAR XP Application 1.

Primer shall be allowed to cure for a minimum of twelve hours at 77°F before the PITTCHAR XP is applied.

2.

Before PITT-CHAR XP is applied, primed substrate shall be cleaned of dirt, dust, grease, oil, loose material, or other matter that may adversely affect PITT-CHAR XP bond.

3. PITT-CHAR XP shall be applied in accordance with PITT-CHAR XP project Manual.

8.6

4.

PITT-CHAR XP materials shall be kept within a temperature range of 86°-93°F for 24 hours prior to use with a plural pump with heated holding tank.

5.

PITT-CHAR XP shall be applied using plural component spray equipment from PPG approved suppliers; Spray Quip Inc., Spraypump, Airtech or Covercat.

6.

Operating parameters for plural component spray equipment shall be in accordance with current Project Application Manual.

7.

PITT-CHAR XP shall be applied to a minimum thickness of 13.2 mm per UL Design XR 612 for 2 hour rating (UL 1709 certification directory). a.

Minimum thickness at any one point shall not be less than 85% of specified thickness.

b.

Overall average thickness shall be equal to, or greater than, the UL specified thickness.

c.

UL certified thickness is based on the average thickness.

Reinforcing Mesh Application 1.

Reinforcing mesh shall be cut and bent to fit the flange thickness plus 5-6mm coating applied and cured (1 coat) before the Pitt-Char XP is applied.

2.

Mesh sections shall be cut from a roll 2, 3 or 4 foot wide and bent on a 4 ft wide minimum brake to ensure straight crisp bends. The ½ x ½ x 19 gage galvanizes steel mesh shall be




29-JUL-2011

Page: 39 of 48 bent to fit 2-4 inches from flange edge toward the web in a “U” shape per attached drawing. The bent mesh sections will be attached using a friction fit method on full flanges.

8.7

3.

3 sided beams shall have the inner top flange meshed by laying the uncoated flange facing down, fireproofing the 3 sides and lying in the flat mesh sections onto the first coat of PittChar XP before cure. An option for pre erected 3 sided steel beams is to attach weld pins 2mm diameter x 25-50mm long in two rows 300mm centers on each half flange face to secure the mesh in an inverted position after the first coat of Pitt-Char XP has cured by bending the pins over the mesh to secure.

4.

Adjacent pieces of steel mesh shall be butt joined at seams with a 25mm maximum gap.

5.

Mesh shall be installed after approximately 5-6mm of Pitt-Char XP has been applied.

6.

Second coat of Pitt-Char XP shall be troweled or rolled into mesh to ensure complete encapsulation with no voids or mesh edges protruding from the coating.

Topcoat Application 1.

Topcoat of either Sigmadur 550 or Amercoat 450H shall be applied per PPG recommendation.

2.

Unless otherwise specified, topcoat shall be applied within seven days after the PITT-CHAR XP is applied. If the seven days are exceeded, the surface of the PITT-CHAR XP shall be sweep blasted or mechanically abraded with 40 grit paper (or equivalent) and solvent cleaned prior to applying the topcoat.

3. Topcoat shall be applied to a minimum DFT of 2 to 3 mils. 9.

Inspection, Testing, and Repair 9.1

Daily Production Samples and Tests 1.

2.

Daily production samples shall be taken one per shift. Additional samples shall be taken if material batch numbers change. This can be accomplished by spraying material into a plastic cup and identifying sample number and date. a.

Samples shall be tested randomly to determine fireproofing hardness and density properties.

b.

Sample shall be documented on the PITT-CHAR XP Fireproofing Daily Log.

The following inspections and tests shall be performed on a daily basis. a.

Degreasing stage – surface contamination – Visual, white cloth check for oils or other harmful contaminates [SOVENT WIPE TEST]

b.

Blast cleaning – Visual inspection to ensure sheen surfaces are dulled by sweep blasting steel [VISUAL]

c.

Primer – Wet film thickness measurements primer [WET FILM GAGE]

d.

Inspect spray equipment – Operating conditions of plural component equipment [MATERIAL RATIO WEIGHT CHECK]

e.

Application of PITT-CHAR XP – Inspect wet film thickness with approved wet film probe [Bridge Gage], observe mesh installation




29-JUL-2011

Page: 40 of 48

9.2

PITT-CHAR XP dry film gage [Elcometer or similar] capable of measurements for the specified Pitt-Char XP thickness and a calibrated probe such as a digital caliper to be inserted in a predrilled 1/8” hole or as required to measure steel meshed areas.

g.

Inspect cure of PITT-CHAR XP – [DUROMETER SHORE D]

h.

Topcoat – Inspect application of topcoat [WET FILM THICKNESS / visual after cure)]

i.

Environmental test equipment – Sling pychrometer, surface thermometer

Deficiency Inspection and Repair 1.

9.3

f.

Deficiencies in the fireproofing shall be inspected, noted, and properly repaired. Deficiencies include, but are not limited to, the following: a.

Cracks or seams of any length in PITT-CHAR XP.

b.

Disbondment of primer, PITT-CHAR XP, or topcoat

c.

Exposed reinforcing mesh

d.

Inadequate fireproofing thickness.

e.

Excessive mills and subsequent coating runs, drips, spills, and curtains.

2.

Repair of deficiencies shall conform to procedures as stated in the project Pitt-Char XP Manual. If necessary, manufacturer shall write a repair procedure not cover in the Manual.

3.

A written repair procedure shall be submitted to the Purchaser before repairs are performed.

Hardness Test 1. PITT-CHAR XP shall have a minimum Shore D value 24 hours after PITT-CHAR XP application of 25 and >35 before application of the topcoat. 2.

Shore D Hardness test shall be performed using a Shore D gauge.

3. PITT-CHAR XP shall have a fully cured Shore D value greater than 35.

9.4

4.

Hardness readings shall be taken on areas that are relatively smooth.

5.

Ten readings shall be taken per area, discarding the low and high reading.

Density Test 1.

Random daily production samples (see 8.1) of PITT-CHAR XP shall be tested for density a minimum of once per week. 3

2. PITT-CHAR XP shall have a minimum density of 68.7 lbs./ft . 9.5

Final Inspection Final inspection of the installed fireproofing shall be performed jointly by the Applicator and the Purchaser.

9.6

Test Results Test results shall be recorded on “PITT-CHAR XP Customer / Application Quality Control Report” and the “Fireproofing Daily log”.




29-JUL-2011

Page: 41 of 48 10.

Curing Fireproofed surfaces shall not be exposed to the exterior elements until the fireproofing is completely cured and the topcoat is properly sealed over the entire fireproofed surface.

11.

Shipping and Handling All fireproofed steel shall be handled using nylon slings or other approved lifting methods. Proper dunnage during transport, storage and jobsite erection shall be used to minimize damage to the fireproofing. Large heavy steel sections should be lifted with sling on block out areas or lifting points to avoid edge damage to fireproofing.




29-JUL-2011

Page: 42 of 48

Attachment A

Customer Applicator Inspection Quality Report

Project:

Report By:

Client:

Title:

Clients Rep.:

Date:

Applicator:

Area:

______

Procedure below must be signed off by client and applicator.

Procedure

Acceptance

Applicator

Client

Date

Acceptance

Acceptance

Comments

___________

____________

Pin Installation Blasting

____________

Priming

____________

Primer Thickness Mesh Installation

____________

Surface Acceptance

____________

Pitt-Char XP Coating

1st Coat

____________

2nd Coat

____________

3rd Coat

____________

Topcoat

____________

General Comments:_________________________________________________________________ __________________________________________________________________________ Area Complete Signature (Applicator):

Date

Area Accepted Signature (Client):

Date




29-JUL-2011

Page: 43 of 48

Attachment B ®

PITT-CHAR XP COATING

DATE____________

REFERENCE SAMPLE APPROVAL PROJECT: LOCATION: APPLICATOR: DESCRIPTION OF SAMPLE:

LOCATION OF SAMPLE: APPLICATION EQUIPMENT (  ): HAND TROWEL ( ) PITT-CHAR THICKNESS:

PLURAL AIRLESS ( ) (mm)

SINGLE POT ( ) (inches)

REINFORCEMENT TYPE ( ):

FIBER GLASS MESH ( ) STEEL MESH ( )

SURFACE FINISH () :

ROLLED ( )

CARBON MESH ( ) PINS/WASHERS ( ) SPRAY ( )

FINISH DESCRIPTION:

APPROVAL SIGNATURES SIGNATURE

TITLE

COMPANY

DATE

APPLICATOR FABRICATOR CLIENT OTHER PPG FORM # 4 REVISED 3/97




29-JUL-2011

Page: 44 of 48

Attachment C:

Plural Spray Equipment Report

Customer:

Date:

Location:

Applicator:

Project:

Report by:

Plural Fireproofing Equipment Machine Type Hose length Preloading Pitt-Char XP temperature

Part A:

Part B:

Tank Temperature

Part A:

Part B:

Tank Pressures

Part A:

Part B:

In-line heater temperatures

Part A:

Part B:

Displacement pump pressures

Part A:

Part B:

Line Heat Gun exit temperature Spray gun

tip size: NOTES

Signature Site manager - Site QA/QC Manager




29-JUL-2011

Page: 45 of 48

Attachment D

Daily Application Log

Customer:

Date:

Location:

Applicator:

Project:

Report by:

Personnel Site Manager:

Foreman:

Weather Data Time

Air

Wet Bulb

Dry Bulb

% RH

Surf. Temp.

Dew Pt.

Plus/Minus

Structures Coated

Coating Thk. (mils)

Reinforcement

Material Temperature ºC

Component A:

Component B:

Conditions

Batch Numbers and Quantity Component A

Number Pails

Component B

Number Pails

Type of Spray Equipment: Surface Preparation: Primer / Thickness (mil) Topcoat / Thickness (mil) Pump Ratio (Plural) Time "A" Weight

"B" Weight

Pump Ratio A:B




29-JUL-2011

Page: 46 of 48

Attachment E

Fire Resistance Ratings - ANSI/UL 1709 See General Information for Fire Resistance Ratings - ANSI/UL 1709

Design No. XR612 May 03, 2011 Ratings — 1, 1-1/2, 2, 2-1/2, 3, 3-1/2 and 4 Hr (See Item 3)

1. Steel Column — Min size W10x49 (min. W/D = 0.84, min. Hp/A = 159). The column surfaces shall be free of dirt, loose scale and oil. Steel surfaces to be primed with polyamide-epoxy or zinc rich primers to an approximate dry film thickness of 0.003 in. 2. Reinforcing Mesh — Carbon fiber mesh with a 1/4 by 1/4 in. sq pattern (four squares per inch) weighing 2 oz/sq yd, wrapped around the column flanges and flange tips. Mesh embedded at approximately mid-depth of mastic coating. Long direction of mesh installed lengthwise along column, with joints overlapped min. 2 in. 2A. Glass Fiber Mesh — As an alternate to Item 2 for the 1 hr rating only, glass fiber mesh, 6 in. wide, weighing 4.5 oz/sq yd embedded at approximately mid-depth of mastic coating. 2B. As an alternate to Items 2 and 2A, — 1 in. hexagonal wire mesh (No. 20 SWG galv steel wire), wrapped around the column flanges and secured in position by means of Type C furring clips spaced approximately 12 in. apart. Mesh embedded at approximately mid-depth of the coating. 2C. As an alternate to Items 2, 2A and 2B, — 1/2 by 1/2, No. 19 SWG galv steel welded wire mesh. Butt ended mesh bent to fit tightly over the flange edges along the column length. Galv or stainless steel flange edge clips shall be used when the required coating thickness exceeds THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.



29-JUL-2011

Page: 47 of 48

0.50 in. The clips shall be placed at ends of mesh and shall be spaced a max 24 in. OC. The mesh shall be fastened together across the flange faces with galv wire of 22 gauge or larger. 2D. As an alternate to Items 2, 2A, 2B and 2C, — 1-1/2 in. by 1-1/2 in. welded steel hardware cloth formed from No. 20 MSG hot dipped galv steel wire or 1/2 by 1/2, No. 19 SWG galv steel welded wire mesh. Mesh secured to the column with 5/16 in. wide by 3/16 in. deep steel staples formed from 0.024 in. thick galv steel. Mesh placed at approximately mid-depth of the coating and extending 2 in. to 4 in. from flange tips on flange faces. 2E. As an alternate to Items 2, 2A, 2B, 2C and 2D, — No. 20 SWG galv steel wire twisted to form 1 in. hexagons or 1/2 by 1/2, No. 19 SWG galv steel welded wire mesh. Mesh placed at approximately mid-depth of the coating and extending 2 in. to 4 in. from flange tips on flange faces. 2F. As an alternate to Items 2, 2A, 2B, 2C, 2D and 2E, — 1/2 by 1/2 in. No. 19 SWG galv steel welded wire mesh, approximately 8 in. wide, centered over flange edges and bent over 10 SWG wire spacers. Spacers installed across each flange on nominal 18 in. centers. Mesh fastened in place at each spacer with 10 SWG formed wire clip. 3. Mastic Coating* — Coating spray applied directly from containers to the appropriate thicknesses shown in the table below. Rating Hr.

Material Thickness, in.

Material Thickness, mm

1

0.28

7.1

1-1/2

0.40

10.2

2

0.52

13.2

2-1/2

0.63

16.0

3

0.75

19.1

3-1/2

0.84

21.3

4

0.90

22.9

PPG INDUSTRIES INC — Type Pitt-Char XP

*Bearing the UL Classification Mark Last Updated on 2011-05-03


Fireproofing Specification

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