Durasteel brochure v24

Promat DURASTEEL®

High Performance Barrier & Ceiling Systems

UniclassL5:P2:N32

CI/SfB (Rf9) (K2)+(K3)

EPICE1:X2:Y421

Durasteel Brochure.indd 1Durasteel Brochure.indd 1 28/10/08 15:32:5328/10/08 15:32:53

Contents

What is Promat DURASTEEL®? 3

Technical Data & Construction Details 4

Technical Services & System Installation 5

Regulatory Reform (Fire Safety) Order 2005 5

System Performance, Tests and Approvals 6

System Key Features and Benefi ts 8

Promat DURASTEEL® Range 8

Low Radiation Fire Wall 9

Radiation Characteristics 9

Protected Zones, Spandrel Panels, Smoke Screens 10

Valve Protection Enclosures 10

Insulated Fire Wall Systems 12

FIREBLAST® Wall Systems 12

System Applications 13

Specifi cation Details 16

Case Studies 29

Licensee Testimonials 31

Promat DURASTEEL® High Performance Systems

2



WHAT IS Promat DURASTEEL®?Promat DURASTEEL® is a composite panel of fi bre reinforced cement mechanically bonded to punched steel sheets on both outer surfaces. It is classed as ‘non-combustible’ to BS 476: Part 4: 1970 and A1 to Clause 10 of BS EN 13501-1:2002. Promat DURASTEEL® is both highly impact and moisture resistant.

Promat DURASTEEL® has been developed and supported through rigorous testing for use in barriers, door and ceiling applications, with a wide range of specifi cations available.

Promat DURASTEEL® systems combine lightness, strength, impact, blast resistance and durability with exceptional fi re resistance. In addition, Promat DURASTEEL® can also withstand the effects of fi refi ghters’ hoses.

Promat DURASTEEL® systems have been used successfully across the industry for many years, including large rail, metro and airport projects, as well as military developments and commercial, pharmaceutical and petrochemical facilities.

Promat has developed DURASTEEL® to provide an effective blast resistant solution to constructions in a wide range of industrial applications, including power generation and anti-terrorist installations.

HIGH PERFORMANCE SYSTEMSPromat DURASTEEL® walls and partitions can be designed and installed in various layout and framing options to meet a multitude of needs. In today’s construction markets the need for systems which can perform multi-functional roles, whilst capable of allowing for fast track and cost effective installation, are of prime importance.

The Promat DURASTEEL® partition and wall systems can easily fulfi l all of these roles. Promat DURASTEEL® walls have resistance to extreme impact, before, during and after exposure to fi re. This ensures that under use, they suffer no damage from the burden of every day exposure within, for instance, warehouse situations. Under fi re conditions they protect and maintain compartmentation and after a fi re they ensure a building remains secure until remedial work can be undertaken.

Promat DURASTEEL® systems can be installed quickly; on most occasions they have no requirement for additional foundations or other special construction works. Installation is a “dry” trade, thus there is no disruption of other trades working in the same areas, allowing faster project completion.

Promat DURASTEEL® systems can offer both integrity only or integrity and insulation. Walls can be designed for high blast resistance and meet most of the generally recognised fi re curves, including cellulosic and hydrocarbon.

Promat DURASTEEL® systems combine extremely high levels of fi re, impact and water resistance. They are proven to withstand the most demanding environments, temperature extremes, hostile elements and can resist high thermal shock, such as high pressure water hoses.

Promat DURASTEEL® partition and wall systems can be used in applications such as separation of hazardous areas, shielding for valve actuators, protection of escape routes and tunnels, construction of refuge areas, compartmentation within buildings and storage areas for hazardous goods or equipment protection.

ABOUT Promat UK

Promat UK Limited is a market leader in passive fi re protection and high temperature insulation, with a fi re protection range that offers a unique combination of product benefi ts: exceptional strength, impact and moisture resistance, ease of working, installation and safety in use.

Promat UK Limited is a subsidiary of Promat International, which has sales offi ces, factories and workshops worldwide.

Promat DURASTEEL® fi re and impact resistant systems provide a cost effective fast track solution for the compartmentation of large warehouses and fi re resistant enclosures, rooms, ceilings, cable trunking and similar applications.

Promat DURASTEEL® systems can be fi tted with a range of compatible personnel doors, sliding and guillotine doors, roller shutters and access hatches to provide up to 240 minutes fi re resistance.

3



General Technical data

Material class Non-combustible

Surface spread of fl ame Class 1

Building Regulations classifi cation Class 0

Alkalinity (approximately) pH (core) 10-13

Thermal conductance (approximately) at 20°C W/m2K 60 (9.5mm)

Coeffi cient of expansion (20-100°C) m/mK 15 x 10-6 (9.5mm)

Nominal moisture content (air-dried) % 6

Moisture movement (ambient-saturated) % –

Thickness tolerance of standard boards +1.0 to -1.0 (9.5mm)

Length x Width tolerance of standard boards mm ±2.0

NOTE: Fire performance fi gures denote integrity (E) and insulation (I) performance respectively.

For details of specifi cations and installation details, please consult Promat Technical Services.

Performance Details

Specifi c Applications Primary Performance Fire Performance

Required (minutes)

Public and service corridors

Warehousing

Industrial buildings

Mass transit systems

Manufacturing facilities

Other areas subject to

abnormally rough use

Offshore facilities

Petrochemical industry

Gas processing plant

Other areas subject to

projectile or explosion risk

Impactresistance

Blastresistance

Board Format Data

Thickness Length x Width Approximate Weight

(mm) (mm) (Kg/m2)

Dry With approx.

6% moisture

6 2500 x 1200 15.9 16.8

9.5 2000 x 1200 19.8 21.0

9.5 2500 x 1200 19.8 21.0

Typical Mechanical Properties

Flexural strength Frupture 6mm Average, dry N/mm2 109

Flexural strength Frupture 9.5mm Average, dry N/mm2 84

Modulus of elasticity E 6mm Average, dry N/mm2 55000

Modulus of elasticity E 9.5mm Average, dry N/mm2 40000

E240E240, El60

E240, El120El240

H0H60

H120

44



5

DESIGN AND TECHNICAL SERVICESWith over 100 years of combined experience, our dedicated technical and sales

support teams are available to provide information and assistance to help in the

design and installation of Promat DURASTEEL® systems.

SYSTEM INSTALLATIONAfter a site survey, installers will provide fully designed working drawings. Promat will

supply the fi re resisting sheets, doors and penetration seals, which provides a single source

and responsibility.

All elements are tested as a combined system to ensure compatibility, with one source of

warranty. Access panels for maintenance or fi re stopping of penetrations through the barrier

can be included in the system estimate.

Promat DURASTEEL® systems are installed by experienced, licensed installers. Once the work

is complete, the system undergoes a thorough check before the installation is issued with a

Certifi cate of Conformity.

Our licensed installers are all assessed under the FIRAS third party accreditation scheme.

REGULATORY REFORM (FIRE SAFETY) ORDER 2005 (RRFSO)Fire safety law changed in October 2006. The emphasis of the new law is prevention of fi res

and reduction of risk, and makes it the property owner’s responsibility to ensure the safety of

everyone who uses their premises and the immediate vicinity.

The Department for Communities and Local Government (DCLG) have produced a set of

guides to advise the responsible person how to comply to the fi re safety law, help them to

conduct a fi re risk assessment and identify general fi re precautions that will need to be put in

place.

Failure to meet the requirements of these new regulations could lead to prosecution, which

could then result in hefty fi nes or even imprisonment. The Order replaces any previous fi re

legislation. Any fi re certifi cates issued under the Fire Precautions Act 1997 ceased to have effect

from 1st October 2006.

Promat provides a free advice service to help parties within the building industry to make the

right choices in fi re safety. Promat’s technical department monitors any changes and tests

systems in order to offer solutions to help comply with fi re safety legislation.



The picture right shows a Promat DURASTEEL® wall undergoing impact following a fi re test. The picture above shows a concrete block wall undergoing similar testing.

Single-skin E60, E120, E240 or E360 Marine Classifi cation A0 Constructions (A and B class), H0

Double-skin EI 60, EI 90, EI 120, EI 180 Marine Classifi cation A60 Constructions or EI 240 for standard fi re tests H60 and H120 ratings for hydrocarbon fi re tests.

Special Constructions

Type Building & Construction Offshore Constructions

SYSTEM PERFORMANCE

Promat DURASTEEL® has been designed and installed in many purpose built fi re walls, which provide special performance characteristics beyond fi re resistance. All structures can be independently assessed to ensure the required performance is achieved.

SYSTEM TESTS AND APPROVALSPromat DURASTEEL® systems have been tested extensively in the UK to comply to all relevant

parts of BS 476, as well as many internationally recognised approvals such as: Factory Mutual

(FM), Underwriters Laboratories (UL), Underwriters Laboratories Canada (ULC), Det Norske

Veritas (DNV), Lloyds Register of Shipping (LRS), Zulassung, EDF and LUL. The systems have

also achieved the stringent Certifi re approvals.

Over £2.5M has been spent on tests, assessments and approvals to comply with many

insurance specifi c requirements, both in the UK and overseas.

Promat has completed investigative programmes at our facilities in Belgium and the UK.

DURASTEEL® is manufactured in accordance with independently accredited BS EN ISO 9001

quality and ISO 14001 environmental management systems.

6



The picture above shows a Promat DURASTEEL® wall being fi re tested to E240. Below are examples of Promat DURASTEEL® UK and International certifi cation.

7


SYSTEMS AVAILABLESome common partition systems constructed from Promat DURASTEEL® are shown on the

following pages. When considering the design of walls, it is essential to consider the section

size of the steel framing in conjunction with the wind loading factors, expansion allowance,

together with the height and span of the wall, to ensure that under both ambient and fi re

conditions, the wall will provide the necessary design performance. The basic framing system

comprises of lightweight steel sections, with a nominal 3mm thickness, dependant on the other

design factors etc. All framing is either bolted, screwed or welded into position, dependant on

location, performance parameters and design requirements.

Where a cold smoke seal is required, the boards must be bedded on PROMASEAL® fi re rated

silicone or PROMASEAL® Intumescent mastic. For demountable wall systems, to ensure

sealants do not act as adhesives, a cold smoke seal composed of a 2mm thick strip of Promat

PL Intumescent strip can be applied. For integrity only systems, Promat DURASTEEL® walls

have been tested with the framework on both the exposed and unexposed face to fi re, in

order to show that the frame can be exposed without detriment to the fi re performance of the

system.

The framing for the Promat DURASTEEL® wall systems must be securely fi xed back to a

substrate (concrete, masonry or steel) that has an equal or better fi re performance than

the designed wall. All fi xings must be non-combustible, and must be listed in the approval

documents. Expansion bolts used to fi x framework should be steel, not aluminium or plastic.


KEY BENEFITS● Comprehensive technical expertise

● Certifi re accredited systems

● FIRAS accredited and fully qualifi ed

licensed installers

● Guaranteed system with full certifi cate

of conformity

● Tested to comply to UK and

international standards

● Insurance industry recognition

● System fully fi re tested to conform

to new RR(FS)O standards

● Tested with a range of service

penetrations and fi re doors

● No maintenance ‘fi t and forget’ system

● Over 40 years service life

● High speed of installation

8

KEY FEATURES:

• Up to EI 240 and E 360 fi re rating

• Impact resistant

• Unaffected by water

• Non-combustible

• Minimal smoke or toxic gas in a fi re

• Slim, space-saving profi le

• Lightweight, no foundations

• Easily relocatable

• Hose-stream resistant

• Mechanical or seismic vibration resistant

• Suitable for retro-installation

• Low sound transmission

• Good acoustic insulation performance


Distance from After 30 After 60 After 120 After 240 barrier (metres) minutes minutes minutes minutes

0.5 7.5 12.0 16.0 20.0

1.5 4.6 7.1 9.8 12.5

2.5 2.5 3.9 5.4 6.9


LOW RADIATION FIRE WALLLow radiation fi re wall for constructions that require a high degree of stability, integrity

and insulation as measured upon the unexposed surface of the wall is not critical, but

where heat radiation from exposed to unexposed face could be of importance. Promat

DURASTEEL® low heat radiation walls offer a lightweight construction, which is very narrow

across its thickness.

Used in conjunction with the Promat DURASTEEL® pallet racking fi re barrier system,

this wall offers increased warehousing space and allows for racking to be placed practically

against the Promat DURASTEEL® wall itself.

Single layer Promat DURASTEEL® fi re walls can be constructed using framing of either steel

channels, Tee sections or back to back angle sections. The type of framing system and

the dimensions of the steel sections will depend on the performance requirements of the

wall in terms of wind load, fi re performance and impact resistance. In these circumstances,

Promat DURASTEEL® walls provide a bespoke solution.

RADIATION CHARACTERISTICSRadiation levels measured during a test on a single skin 9.5mm Promat

DURASTEEL® barrier

Effects of Thermal Radiation

Radiation Heat Flux (kW/m2) Observed effect

0.67 Summer sunshine in the UK

12.5 Piloted ignition of timber

29 Spontaneous ignition of timber

Radiation Levels (kW/m2)

9



PROTECTED ZONES, SPANDREL PANELS, SMOKE SCREENSSmoke kills more people in fi res than heat, fl ames or structural collapse. It is therefore

recognised that occupant safety in a fi re can be greatly improved by providing an

effi cient smoke extraction system. Part of an engineered smoke control system may

involve the provision of smoke reservoirs, the use of smoke channelling screens and

smoke curtains.

Testing standards for smoke control equipment smoke curtains and screens shall meet

the requirements of BS 7346: Part 3: 1990, which requires the screen to withstand a

fi re temperature of 600°C +/-20°C for a minimum of 30 minutes.

The Promat DURASTEEL® system has been tested to the criteria of BS 476:

Part 20, which has much higher exposure temperature requirements and it provided a

performance in excess of 240 minutes. Promat DURASTEEL® barriers can also be

used in position as horizontal “wings” (protected zones) at the head and to the sides of fi re

walls, forming an added “band” of protection at the junction with other substrates (as detailed

in the FPA Design Guide Supplement 2004). This makes it exceptionally diffi cult for fi re to

breach a roof and thus leap over the top of, or around, the fi re resistant wall system.

Promat DURASTEEL® can also be used within spandrel panel systems, positioned at the end

of fl oor slabs in order to prevent fi re bridging gaps between fl oor slabs and curtain

wall systems.

VALVE PROTECTION ENCLOSURESThe ability to isolate storage areas or to direct highly combustible fuels away from

a heat source through a series of protected valves is paramount in the event of fi re.

When subjected to high temperatures, the plastic parts of a valve can easily be rendered

inoperative, resulting in the valve’s inability to divert or arrest fl ow.

Promat DURASTEEL® can offer different methods of protection for valves, dependent on

the requirement.

In certain circumstances, it may be suffi cient to protect the valve with a fi re resistant

shielding. In other cases, a more substantial form of protection may be required. In these

circumstances, the valve can be fully enclosed within a Promat DURASTEEL® valve actuator

box. These boxes have been designed to ensure the valve temperature cannot rise by

more than 30°C in 15 minutes, or 30°C in 30 minutes, depending on the type of Promat

DURASTEEL® system installed.

10


Promat DURASTEEL® barrier

Typical Penetration details Insulated barrier


11



INSULATED FIRE WALLFire walls are used in constructions where high insulation as well as stability is required during a

fi re. Promat DURASTEEL® insulated fi re walls are designed to prevent the passage of heat from

a fully developed fi re on the exposed face. The maximum permitted temperature rise allowable

on the surface of the unexposed face is 140°C as a mean temperature over all the surface, or a

maximum temperature rise of 180°C at any one point over all the surface.

Insulated wall constructions should be used in areas where the following may occur:

● Escaping personnel or fi re fi ghters may have bodily contact with the wall surface.

● If used as a wall lining to any escape route, for instance as an access tunnel within a factory.

● If there are any volatile chemicals or materials stored within the vicinity of the fi re wall and

which may ignite at low temperatures.

● There is a need to improve compartmentation beyond simple integrity.

There are a number of methods of constructing insulated wall systems. Each option has its

own benefi ts. The type of system, thickness and density of the rock wool and cover strips, if

required, are all dependent on the fi re and physical performance required from the system.

FIREBLAST® WALLDesigned specifi cally to protect personnel and equipment from the effects of explosion,

fi re, impact, and the effects of smoke and fumes in hazardous environments, such as offshore

platforms, petrochemical installations, chemical plants, military establishments, civil defence

works and hazardous process plants.

Additional features of FIREBLAST® fi re and blast resistant walls:

● Blast resistant, tested from 0.3 to 2 bar over pressure.

● Resistant to hydrocarbon fi res, tested to H120.

● Impact resistant to 4000J after 180 minute fi re test. In accordance with DIN 4102 Parts 2

and 3 requirements

● High energy absorption.

● Hose stream resistant to a 5 bar high pressure hose (ASTM E119).

Unlike many fi re and blast resistant materials, Promat DURASTEEL® is non-combustible and will

withstand an explosion followed by a prolonged fi re and still be unaffected by hose stream fi re

fi ghting. Its integrity remains unimpaired, ensuring continued protection against fi re, impact and

moisture as well as preventing the escape of smoke and toxic gases. Promat DURASTEEL®

systems are tested up to H120 fi re rating, and the systems can be designed to suit specifi c

project performance requirements.

All FIREBLAST® walls are individually tailored to suit specifi c project performance requirements,

please consult the Promat Technical Services Department for specifi cation and construction details.

12



Knights of Old DURASTEEL® barrier

SYSTEM APPLICATIONS

Promat DURASTEEL® FOR INDUSTRY

Manufacturing & Warehouse Complex

The need for effective protection of personnel,

plant, stores and property in industry is vital.

Promat DURASTEEL® is proven to contain

fi re within compartments of a production area

or storage facility, thus allowing evacuation of

personnel, minimising disruption of processes

and preventing the destruction of valuable stocks.

Promat DURASTEEL®

FOR TRANSPORTATION

INFRASTRUCTURE

Underground Rail System

Promat DURASTEEL® is lightweight,

robust and ideally suited to the

external environment of all trackside,

station and rolling stock fi re protection

requirements. It is also widely used in

road and rail tunnels.

As an indication of the effectiveness of Promat DURASTEEL® these photographs show a production facility before and after a fi re. The Promat DURASTEEL® wall separating two sections of the factory performed exactly as designed. Indeed, the bottling plant on the unaffected side of the barrier was operational again within 2 days of the fi re, therefore minimising the effects of the incident as much as possible.

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Promat DURASTEEL® FOR COMMERCE

High-Rise Offi ce Block

Promat DURASTEEL® is the fi rst choice fi re protection

product for an impressively wide range of structures,

including high-rise offi ces and hotels, airports, retail

parks, leisure complexes, public buildings and

government institutions.

Promat DURASTEEL® has also undergone rigorous

testing for use in electrical plant rooms and is the

approved system for the numerous EDF installations

throughout London.

Other Promat DURASTEEL® applications may be suitable in high-rise offi ce blocks; e.g. fi re

doors, fuel storage and boiler room enclosures, ceilings above liftshafts, ceilings to fan rooms,

lift door transom panels, curtain wall fi re breaks and penetration seals.

Airport

For every airport operator, one item within their mission statement is to provide for the highest

standard of safety in civil aviation and airport operation. The range of Promat DURASTEEL®

systems for airports are proven to meet or exceed the most rigorous British and International

legislative requirements.

Other Promat DURASTEEL® applications may be suitable in airports; e.g. duct splitters,

riser shafts, transformer enclosures.

14



PROMAT DURASTEEL® FOR NUCLEAR AND FOSSIL FUEL POWER STATIONS

Nuclear/Fossil Fuel Power Stations

In an industry where the concern for environmental protection, coupled with increasing

demand for electrical power, brings constant technology development in both conventional

and new approaches to energy supply, only a system such as Promat DURASTEEL® has

the fl exibility to match the need for innovative solutions.

Promat DURASTEEL® is non-combustible, will withstand prolonged hydrocarbon fi re,

resists hose-stream fi re-fi ghting, is impact and moisture resistant, and does not emit

smoke or toxic gases.

Promat DURASTEEL® FOR HYDROCARBON

Offshore Oil/Gas Production Platform

The light weight and strength of Promat DURASTEEL® combine with its resistance to

hydrocarbon fi re, blast, impact, water and corrosion to make Promat DURASTEEL® systems

the ideal choice for fi re protection on offshore production platforms and in potentially hazardous

land-based environments.

15



Promat DURASTEEL® STANDARD BARRIER SYSTEMS SPECIFICATION DETAILS

Height of Size of channel for single Size of channel for double partition (metres) skin uninsulated partition skin insulated partitions (mm x mm x mm) (mm x mm x mm)

0 – 6 80 x 60 x 3 80 x 60 x 3 6 – 9 150 x 60 x 3 150 x 60 x 3 9 – 12 Two 150 x 60 x 3 back to back Two 150 x 60 x 3 back to back 12 – 15 Two 175 x 60 x 3 back to back Two 200 x 60 x 3 back to back

Stud Channel Sizes

Insulated Partitions

Fire resistance Minimum stud DURASTEEL® Rock wool infi ll – minutes depth – mm fi llets per face E240 / I120 80 1* 2 x 40mm x 140kg/m3

E240 / I120 150 None 3 x 50mm x 80kg/m3

E240 / I240 80 2* 3 x 40mm x 140kg/m3

E240 / I240 150 2* 3 x 50mm x 100kg/m3

Stud Channel Sizes

Height of Size of steel channel (mm x mm x mm) for fi re resistance partition – m period (minutes)

60 mins 90 mins 120mins 180mins 240mins 0 – 6 80 x 60 x 3 80 x 60 x 3 80 x 60 x 3 80 x 60 x 3 80 x 60 x 3 6 – 9 80 x 60 x 3 80 x 60 x 3 150 x 60 x 3 150 x 60 x 3 150 x 60 x 3 9 – 12 150 x 60 x 3 150 x 60 x 3 150 x 60 x 3 150 x 60 x 3 150 x 60 x 3 12 – 15 150 x 60 x 3 175 x 60 x 3 175 x 60 x 3 175 x 60 x 3 2 no. 150 x 60 x 3 back to back

Insulated Partitions

Board confi guration either side of steel channel Fire resistance Thickness of Thickness of – minutes PROMATECT® -250 (mm) DURASTEEL® (mm) E240, El60 12 6 E240, El90 12 9.5 E240, El120 15 9.5 E240, El180 20 9.5 E240, El 240 25 9.5

PAINTING AND DECORATINGPromat DURASTEEL® is self-fi nished

in either galvanised or stainless

steel and requires no decoration.

If decoration is required, Promat

DURASTEEL® should be de-greased

with a solvent based cleaning agent

before any form of decoration is

applied. Seek paint manufacturers

recommendations.

MAINTENANCE AND CLEANINGPanels do not normally require any

maintenance in use. If panels are

damaged they should be replaced

rather than repaired in order to

ensure fi re performance

is maintained.

SPECIFICATION DETAILSThe following pages details the specifi cations for the range of standard barriers, composite

barriers and suspended ceilings offered. If you require advice on bespoke systems please

contact Technical Services on 01344 381400.

Promat DURASTEEL® COMPOSITE BARRIER SYSTEMS SPECIFICATION DETAILS

For Standard barriers specifi cation details see pages 18-19.

*Fillets must overlap the channels by at least 20mm on both sides. For Composite barriers specifi cation details see

pages 25-27.

See pages 20-24 for suspended

ceiling specifi cations. For self

supporting ceilings please refer to

the Promat Technical department

on 01344 381400.

PROMAT DURASTEEL® SUSPENDED CEILING SPECIFICATION DETAILS

CF418 – Doorsets

CF424 – Partitions and Ceilings

CF480 – Ductwork

CF607 – Composite Barriers

16

CF418 D



240 MINUTE DURASTEEL® PROTECTED ZONE (E 240 - EI 15)

If a fi re breaks out near the area where a compartment wall meets a roof, there is a risk

that it will spread over the roof to the adjoining compartment. To reduce the risk, Approved

Document B requires protection to be installed to a protected zone of the roof 1500mm either

side of the compartment wall. However, for more onerous circumstances, the FPA Design

Guide suggests a minimum of 2500mm, or up to 5000mm dependent upon the orientation of

the ridge and the presence of a sprinkler system.

A DURASTEEL® protected zone detail is required for instances where a DURASTEEL®

fi re barrier (acting as a compartment wall) abuts a roof system. Please contact Promat UK

Technical Services department for further information.

17



DURASTEEL® Fire Barrier E 240 Integrity only (formerly STI 240)Fire resistance: 240 minutes integrity only. (Fire attack from either face)

(formerly referred to as the STI 240 system)

Channel (minimum): 80mm x 60mm x 3mm (for heights up to 6m)

Overall width: 89.5mm

Weight (nominal): 27kg/m2

Estimated sound reduction: 33dB

Perimeter channels fastened to surrounding construction with M10 or M12

all-steel expanding anchors (or equivalent for alternative types of supporting

construction) at 500mm maximum centres.

The vertical channels are set at a maximum 1200mm centres. Horizontal and

vertical channel members either welded together or joined with steel angle cleats,

minimum 60mm x 60mm x 3mm thick x 60mm long, fastened to each channel

member with two M10 steel bolts and nuts.

A single layer of 9.5mm DURASTEEL® fi xed on one side of channel with M5.5 steel

self drill and tap Tek screws at 250mm nominal centres. Fixings a minimum of

12mm from edge of sheet and a maximum of 50mm from corners. Length of fi xing

to be suffi cient to ensure appropriate penetration of screw thread in accordance

with screw manufacturer’s recommendations.

Vertical board joints coincide with studs, horizontal board joints are backed by

steel channel the same size as the vertical studs.

Expansion allowance will be required for barriers above 4 metres high. Please

contact Promat UK Technical department for further information.

DURASTEEL® Fire Barrier E 240 – EI 60 (formerly STI 240/60)Fire resistance: 240 minutes integrity - 60 minutes insulation.

(Fire attack from either face)

(formally referred to as the STI 240/60 System)


Overall width: 118mm










9.5mm DURASTEEL® fi llet fi xed on both sides of channel. Fillet strips to overlap channel by

minimum of 20mm on both sides.

9.5mm DURASTEEL® sheets fi xed through fi llet on both sides of the channel with M5.5

steel self drill and tap Tek screws at 250mm nominal centres. Fixings a minimum of

12mm from edge of sheet and a maximum of 50mm from corners. Length of fi xing to be

suffi cient to ensure appropriate penetration of screw thread in accordance with screw

manufacturer’s recommendations.

Vertical board joints coincide with studs, horizontal board joints are backed by steel channel

the same size as the vertical studs. Expansion allowance will be required for barriers above

4 metres high. Please contact Promat UK Technical department for further information.

Back to back channels fastened together with M10 steel bolts and nuts at 500mm maximum centres. The vertical joints in the DURASTEEL® should be offset by 30mm from

the centreline of the back-to-back studs, to avoid a straight through path for hot gases. Horizontal channels are single channels.

Back to back channels fastened together with M10 steel bolts and nuts at 500mm

maximum centres. The vertical joints in the DURASTEEL® should be offset by 30mm

from the centreline of the back-to-back studs, to avoid a straight through path for hot

gases. Horizontal channels are single channels.

Steel channel sizes for barrier heights up to 15 metres

Height of Channel size Estimated Sound

Barrier (m) (mm x mm x mm) Insulation Rw (dB)

0 – 6 80 x 60 x 3 33

6 – 9 150 x 60 x3 33

9 – 12

Two 150 x 60 x 3 33

back to back

12 – 15

Two 175 x 60 x 3 33

back to back

DURASTEEL® FIRE BARRIER SPECIFICATIONS


Height of Channel size Durateel fi llets Rock wool Estimated Sound

Barrier (m) (mm x mm x mm) per face infi ll Insulation Rw (dB)

0 – 6 80 x 60 x 3 1 None 42

6 – 9 150 x 60 x3 1 None 42

9 – 12 Two 150 x 60 x 3 back to back 1 None 42

12 – 15 Two 200 x 60 x 3 back to back 1 None 42

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DURASTEEL® FIRE BARRIER SPECIFICATIONS

DURASTEEL® Fire Barrier E 240 – EI 120 (formerly STI 240/120)Fire resistance: 240 minutes integrity - 120 minutes insulation.

(Fire attack from either face) (formally referred to as the STI 240/120 System)


Overall width: 118mm










9.5mm DURASTEEL® fi llet strips fi xed on both sides of channel, number of fi llet

strips according to requirements in Table below. Fillet strips to overlap channel

DURASTEEL® Fire Barrier EI 240 (formerly STI 240/240)Fire resistance: 240 minutes integrity - 240 minutes insulation. (Fire attack from either face) (formally referred to as the STI 240/240 System)Channel (minimum): 80 x 60 x 3 (for heights up to 6m)Overall width: 137mmWeight (nominal): 72kg/m2


Perimeter channels fastened to surrounding construction with M10 or M12 all-steel expanding anchors (or equivalent for alternative types of supporting construction) at 500mm maximum centres.

The vertical channels are set at a maximum 1200mm centres. Horizontal and vertical channel members either welded together or joined with steel angle cleats, minimum 60mm x 60mm x 3mm thick x 60mm long, fastened to each channel member with two M10 steel bolts and nuts.

9.5mm DURASTEEL® fi llets fi xed on both sides of channel, number of fi llet strips according to requirements in Table below. Fillet strips to overlap channel by

minimum of 20mm on both sides.

by minimum of 20mm on both sides. 9.5mm DURASTEEL® sheets fi xed through the fi llet

on both sides of channel, with M5.5 steel self drill and tap Tek screws at 250mm nominal

centres. Fixings a minimum of 12mm from edge of sheet and a maximum of 50mm from

corners. The length of fi xing to be suffi cient to ensure appropriate penetration of screw

thread, in accordance with manufacturer’s recommendations. Vertical board joints coincide

with studs, horizontal board joints are backed by steel channel the same size as the vertical

studs. Rock wool infi ll, according to the table below, is fi tted into the channels. The layers

are staggered by a minimum of 150mm.

If the rock wool does not fi ll the cavity, it must be fastened into position with 2.5mm-

diameter steel stud-welded pins and 38mm-diameter spring steel washers. The pins are

positioned in a grid 400mm x 400mm maximum. Expansion allowance will be required for

barriers above 4 metres high. Please contact Promat UK Technical department for

further information.

9.5mm DURASTEEL® sheets fi xed through the fi llet on both sides of channel, using M5.5 steel

self drill and tap Tek screws at 250mm nominal centres. Fixings a minimum of 12mm from edge

of sheet and a maximum of 50mm from corners. The length of fi xing to be suffi cient to ensure

appropriate penetration of screw thread, in accordance with manufacturer’s recommendations.

Vertical board joints coincide with studs, horizontal board joints are backed by steel

channel the same size as the vertical studs.

Rock wool infi ll, according to the table below, is fi tted into the channels. The layers are

staggered by a minimum of 150mm. If the rock wool does not fi ll the cavity, it must be

fastened into position with 2.5mm-diameter steel stud-welded pins and 38mm-diameter

spring steel washers. The pins are positioned in a grid 400mm x 400mm maximum.

Expansion allowance will be required or barriers above 4 metres high. Please contact

Promat UK Technical department for further information.








0 – 6 80 x 60 x 3 1 2 x 40mm x 140kg/m3 47

6 – 9 150 x 60 x3 None 3 x 50mm x 80kg/m3 51

9 – 12 Two 150 x 60 x 3 back to back None 3 x 50mm x 80kg/m3 51

12 – 15 Two 200 x 60 x 3 back to back None 4 x 50mm x 60kg/m3 53




0 – 6 80 x 60 x 3 2 3 x 40mm x 140kg/m3 50

6 – 9 150 x 60 x3 2 3 x 50mm x 100kg/m3 55

9 – 12 Two 150 x 60 x 3 back to back 2 3 x 50mm x 100kg/m3 55

12 – 15 Two 200 x 60 x 3 back to back 1 4 x 50mm x 80kg/m3 56

19



DURASTEEL® SUSPENDED CEILING MEMBRANE

(E 240 - Integrity Only) Fire from above or belowFire resistance: 240 minutes integrity only. (Fire attack from above or below)

Channel (minimum): 80mm x 60mm x 3mm

Overall depth: 89.5mm


Perimeter channels of ceiling membrane fastened to surrounding construction

with M10 or M12 allsteel expanding anchors (or equivalent for alternative types of

supporting construction) at 500mm maximum centres.

Primary channels at 1200mm maximum centres, supported from building structure

above the ceiling membrane with steel drop rods at 1.5m centres. Threaded rods pass

through clearance holes in the upper fl ange of the channels and are fastened with steel

hexagon full nuts.

Diameter of drop rods such that the tensile stress within the rods does not exceed

6N/mm2 for fi re ratings up to 240 minutes. (This may be increased to 10N/mm2 if only

a 120 minutes fi re rating is required).

9.5mm DURASTEEL® boards fastened to lower fl ange of steel channels with M5.5

steel self-drill and tap Tek screws at 200mm nominal centres. Fixings a minimum of


to be suffi cient to ensure appropriate penetration of screw thread in accordance with

screw manufacturer’s recommendations.

Longitudinal board joints coincide with primary channels, transverse board joints

backed by steel channel the same size as the primary channels. Longitudinal and

transverse channel members are either welded together or joined with steel angle

cleats, minimum 60mm x 60mm x 3mm thick x 60mm long, fastened to each channel


Where an expansion allowance is provided within the primary channels, steel jointing

channels, minimum 50mm fl anges x 3mm thick, are fastened to the primary channels

with M10 steel bolts and nuts. The width of the jointing channel (web dimensions)

should be such that it is a close fi t within the primary channels.

On one side of the expansion gap the primary and jointing channels are connected

with minimum two M10 bolts. On the opposite side the channels are connected,

through slotted holes, with minimum two M10 bolts fi tted with fusible washers.

For fi re attack from below, an expansion allowance of at least 6mm per metre is

required for primary channels longer than 4m.

For fi re attack from above, an expansion allowance of at least 6mm per metre is

required for all sizes of ceiling.

As drop rods support the ceiling, the length and width of ceiling membrane

is unrestricted.


(E 240 – EI 120) Fire from belowFire resistance: 240 minutes integrity – 120 minutes insulation.

(Fire attack from below)





with M10 or M12 all steel expanding anchors (or equivalent for alternative types of





hexagon full nuts.




9.5mm DURASTEEL® fi llet strips fi tted over the upper and lower faces of the channel

members. Fillets must overlap the channels by at least 20mm on both sides.

9.5mm DURASTEEL® boards fastened (through fi llet strips) to lower fl ange of steel

channels with M5.5 steel self-drill and tap Tek screws at 200mm nominal centres.

Fixings a minimum of 12mm from edge of sheet and a maximum of 50mm from

corners. Length of fi xing to be suffi cient to ensure appropriate penetration of screw

thread in accordance with screw manufacturer’s recommendations.


backed by steel channel the same size as the primary channels.

Longitudinal and transverse channel members are either welded together or joined

with steel angle cleats, minimum 60mm x 60mm x 3mm thick x 60mm long, fastened

to each channel member with two M10 steel bolts and nuts.

Rock wool insulation 80mm x 140 kg/m3 nominal density, fi tted over the soffi t layer of

DURASTEEL® by fi lling the channels. Joints in layers of rock wool overlap by at least 150mm.










As drop rods support the ceiling, the length and width of ceiling membrane is unrestricted.

DURASTEEL® CEILING SPECIFICATIONS

20




(EI 120) Fire from above or belowFire resistance: 120 minutes integrity and insulation (Fire from above or below)


Overall depth: 166mm








hexagon full nuts.

Diameter of drop rods such that the tensile stress within the rods does not

exceed 10N/mm2.

6 mm DURASTEEL® boards fastened to lower fl ange of steel channels with M5.5 steel

self-drill and tap Tek screws at 200mm nominal centres. Fixings a minimum of 12mm

from edge of sheet and a maximum of 50mm from corners. Length of fi xing to be

suffi cient to ensure appropriate penetration of screw thread in accordance with screw

manufacturer’s recommendations. Longitudinal board joints coincide with primary

channels, transverse board joints backed by steel channel the same size as the

primary channels.




Rock wool insulation 80mm x 140 kg/m3 nominal density, laid over the steel channels.

Joints in layers of rock wool overlap by at least 150mm.













is unrestricted.


(E 240 – EI 120) Fire from above or below (Method 1)Fire resistance: 240 minutes integrity – 120 minutes insulation (Fire from above or below)










hexagon full nuts.




9.5 mm DURASTEEL® boards fastened to lower fl ange of steel channels with M5.5

steel self drill and tap Tek screws at 200mm nominal centres. Fixings a minimum of









Rock wool insulation 80mm x 140 kg/m3 nominal density, laid over the steel channels.

Joints in layers of rock wool overlap by at least 150mm.













is unrestricted.


21



22


(E 240 – EI 120) Fire from above or below (Method 2)Fire resistance: 240 minutes integrity – 120 minutes insulation

(Fire from above or below)

Channel (minimum): 60mm x 150mm x 60mm x 3mm









hexagon full nuts.




9.5 mm DURASTEEL® boards fastened to upper and lower fl ange of steel channels

with M5.5 steel self drill and tap Tek screws at 200mm nominal centres. Fixings

a minimum of 12mm from edge of sheet and a maximum of 50mm from corners.

Length of fi xing to be suffi cient to ensure appropriate penetration of screw thread in

accordance with screw manufacturer’s recommendations.







DURASTEEL® by fi lling the steel channels. Joints in layers of rock wool overlap by at least

150mm.









required for primary channels longer than 4m. For fi re attack from above, an expansion

allowance of at least 6mm per metre is required for all sizes of ceiling.


is unrestricted.


(EI 240) Fire from belowFire resistance: 240 minutes integrity & insulation. (Fire attack from below)










hexagon full nuts.


6N/mm2 for fi re ratings up to 240 minutes.


members. Fillet must overlap the channels by at least 20mm on both sides.

9.5mm DURASTEEL® boards fastened (through fi llet strips) to lower fl ange of steel

channels with M5.5 steel self-drill and tap Tek screws at 200mm nominal centres.

Fixings a minimum of 12mm from edge of sheet and a maximum of 50mm from

corners. Length of fi xing to be suffi cient to ensure appropriate penetration of screw

thread in accordance with screw manufacturer’s recommendations.


















is unrestricted.




23


(EI 240) Fire from above or below (Method 1)Fire resistance: 240 minutes integrity & insulation. (Fire attack from above or below)










hexagon full nuts.



9.5mm DURASTEEL® boards fastened to lower fl ange of steel channels with M5.5

steel self-drill and tap Tek screws at 200mm nominal centres. Fixings a minimum of









Rock wool insulation, total of 120mm x 140 kg/m3 nominal density fi tted with 2 x

60mm thick layers, one layer fi tted over the DURASTEEL® soffi t layer by fi lling the

channels and the second layer fi tted over channels. Joints in layers of rock wool

overlap by at least 150mm.

A layer of 1.5mm thick steel sheet is laid on top of the upper layer of rock wool.













is unrestricted.


(EI 240) Fire from above or below (Method 2)Fire resistance: 240 minutes integrity & insulation. (Fire attack from above or below)










hexagon full nuts.




members. Fillets must overlap the channels by at least 20mm on both sides.

9.5mm DURASTEEL® boards fastened (through fi llet strips) to upper and lower fl ange

of steel channels with M5.5 steel self-drill and tap Tek screws at 200mm nominal

centres. Fixings a minimum of 12mm from edge of sheet and a maximum of 50mm

from corners. Length of fi xing to be suffi cient to ensure appropriate penetration of

screw thread in accordance with screw manufacturer’s recommendations.




















is unrestricted.





(EI 240) Fire from above and below (Method 3)Fire resistance: 240 minutes integrity & insulation. (Fire attack from above or below)










hexagon full nuts.



2 x 9.5mm DURASTEEL® fi llet strips fi tted over the upper and lower faces of the

channel members. Fillets must overlap the channels by at least 20mm on both sides.

9.5mm DURASTEEL® boards fastened (through the fi llet strips) to upper and lower

fl anges of steel channels with M5.5 steel self drill and tap Tek screws at 200mm

nominal centres. Fixings a minimum of 12mm from edge of sheet and a maximum of

50mm from corners. Length of fi xing to be suffi cient to ensure appropriate penetration

of screw thread in accordance with screw manufacturer’s recommendations.




















is unrestricted.


24



DURASTEEL® COMPOSITE BARRIER SYSTEM SPECIFICATIONS

60 minute DURASTEEL® Composite Barrier System (E240 – EI60)Construction

1. Head and base track 80mm x 60mm x 3mm thick steel channel fi xed to fl oor slab and soffi t with M10 or M12 all steel expanding anchors (or equivalent for alternative types of construction) at 500mm maximum centres. Floor slab and soffi t to have minimum of the same level of fi re protection as that required by barrier.

2. Steel channel framework 80mm x 60mm x 3mm channel (1). Vertical channels at maximum 1200 mm centres, Horizontal channels at maximum 2000 mm centres. For partition heights up to 4 metres, horizontal and vertical channel members may be welded together or joined with steel angle cleats, minimum 60mm x 60mm x 3mm thick x 60mm long, fastened to each channel member with two M10 steel bolts and nuts. Above 4 metre height the horizontal and vertical channel members are joined with the angle cleats. Wherever possible, the main vertical channel studs should be formed in one continuous length to avoid the need for splicing.

3. One layer of 12mm thick PROMATECT® -250 (2) fi xed on both sides of the wall using countersunk ribbed timber-fi x Tek screws at 600mm centres. Vertical board joints coincide with studs. Horizontal board joints are fi tted with an internal 100mm wide x 12mm PROMATECT® -250 (4) cover strip, fi xed both sides of the joint with steel drywall screws at 250mm nominal centres.

4. 6mm thick DURASTEEL® sheet (3), fastened to the framework, through the PROMATECT® -250 boards, on both sides of the wall using M5.5 steel self drill and tapping Tek screws at 250mm nominal centres. The length of fi xing to be suffi cient to ensure appropriate penetration of screw thread, in accordance with recommendations from the fi xing manufacturer. Vertical joints coincide with the studs. Horizontal board joints coincide with the horizontal channels or are fi tted with an internal steel cover strip, 100mm wide x 3mm thick, fastened on both sides of the joint with M5.5 steel self drill and tap Tek screws at 250mm nominal centres.


1. Head and base track 80mm x 60mm x 3mm thick steel channel fi xed to fl oor slab

and soffi t with M10 or M12 all steel expanding anchors (or equivalent for alternative

types of construction) at 500mm maximum centres. Floor slab and soffi t to have

minimum of the same level of fi re protection as that required by barrier.

2. Steel channel framework 80mm x 60mm x 3mm channel (1). Vertical channels

at maximum 1200 mm centres, Horizontal channels at maximum 2000 mm

centres. For partition heights up to 4 metres, horizontal and vertical channel

members may be welded together or joined with steel angle cleats, minimum

60mm x 60mm x 3mm thick x 60mm long, fastened to each channel member

with two M10 steel bolts and nuts. Above 4 metre height the horizontal and

vertical channel members are joined with the angle cleats. Wherever possible,

the main vertical channel studs should be formed in one continuous length to

avoid the need for splicing.

3. One layer of 12mm thick PROMATECT® -250 (2) fi xed on both sides of the

wall using countersunk ribbed timber-fi x Tek screws at 600mm centres. Vertical

board joints coincide with studs. Horizontal board joints are fi tted with an

internal 100mm wide x 12mm PROMATECT® -250 (4) cover strip, fi xed both

sides of the joint with steel drywall screws at 250mm nominal centres.

4. 9.5mm thick DURASTEEL® sheet (3), fastened to the framework, through the

PROMATECT® -250 boards, on both sides of the wall using M5.5 steel self drill

and tapping Tek screws at 250mm nominal centres. The length of fi xing to be

suffi cient to ensure appropriate penetration of screw thread, in accordance with

recommendations from the fi xing manufacturer. Vertical joints coincide with the

studs. Horizontal board joints coincide with the horizontal channels or are fi tted

with an internal steel cover strip, 100mm wide x 3mm thick, fastened on both

sides of the joint with M5.5 steel self drill and tap Tek screws at 250mm

nominal centres.

Up to a height of 4m no expansion allowance is required. Above that height an

expansion allowance of at least 6mm per metre height is required. Where an expansion

allowance is provided at the top of a partition, steel channels, minimum 50mm fl anges

x 3mm thick, are fastened to the vertical channels with M10 steel bolts and nuts. The

width of the channel (web dimensions) should be such that it is a close fi t within the

channel studs. At the junction above the expansion gap the channels are connected

with minimum two M10 bolts. At the junction below the expansion gap the channels

are connected, through slotted holes, with minimum two M10 bolts fi tted with fusible

washers. The gap in the DURASTEEL® and PROMATECT® -250 board facing is covered

with a DURASTEEL® and PROMATECT® -250 board cover panel that is fastened to

the steel framework above the gap (through the facing boards) and overlaps the facing

boards below the gap by at least 75mm.













Height of Size of Channel Acoustic Sound

Partition Stud Required Insulation Rw (assessed)

Up to 9m 80mm x 60mm x 3mm thick 42 dB

9m – 15m 150mm x 60mm x 3mm thick 45 dB






1

4 2

3

25





1. Head and base track 80mm x 60mm x 3mm thick steel channel fi xed to fl oor slab and soffi t with M10 or M12 all steel expanding anchors (or equivalent for alternative types of construction) at 500mm maximum centres. Floor slab and soffi t to have minimum of the same level of fi re protection as that required by barrier.



4. 9.5mm thick DURASTEEL® sheet (3), fastened to the framework, through the PROMATECT® -250 boards, on both sides of the wall using M5.5 steel self drill and tapping Tek screws at 250mm nominal centres. The length of fi xing to be suffi cient to ensure appropriate penetration of screw thread, in accordance with recommendations from the fi xing manufacturer. Vertical joints coincide with the studs. Horizontal board joints coincide with the horizontal channels or are fi tted with an internal steel cover strip, 100mm wide x 3mm thick, fastened on both sides of the joint with M5.5 steel self drill and tap Tek screws at 250mm nominal centres.



and soffi t with M10 or M12 all steel expanding anchors (or equivalent for alternative types of construction) at 500mm maximum centres. Floor slab and soffi t to have minimum of the same level of fi re protection as that required by barrier.



4. 9.5mm thick DURASTEEL® sheet (3), fastened to the framework, through the PROMATECT® -250 boards, on both sides of the wall using M5.5 steel self drill and tapping Tek screws at 250mm nominal centres. The length of fi xing to be suffi cient to ensure appropriate penetration of screw thread, in accordance with recommendations from the fi xing manufacturer. Vertical joints coincide with the studs. Horizontal board joints coincide with the horizontal channels or are fi tted with an internal steel cover strip, 100mm wide x 3mm thick, fastened on both sides of the joint with M5.5 steel self drill and tap Tek screws at 250mm nominal centres.



































26




240 minute DURASTEEL® Composite Barrier System (EI240)Construction


and soffi t with M10 or M12 all steel expanding anchors (or equivalent for alternative

types of construction) at 500mm maximum centres. Floor slab and soffi t to have

minimum of the same level of fi re protection as that required by barrier.

2. Steel channel framework 80mm x 60mm x 3mm channel (1). Vertical channels

at maximum 1200 mm centres, Horizontal channels at maximum 2000 mm

centres. For partition heights up to 4 metres, horizontal and vertical channel

members may be welded together or joined with steel angle cleats, minimum

60mm x 60mm x 3mm thick x 60mm long, fastened to each channel member

with two M10 steel bolts and nuts. Above 4 metre height the horizontal and

vertical channel members are joined with the angle cleats. Wherever possible,

the main vertical channel studs should be formed in one continuous length to

avoid the need for splicing.

3. One layer of 25mm thick PROMATECT® -250 (2) fi xed on both sides of the wall

using countersunk ribbed timber-fi x Tek screws at 600mm centres. Vertical

board joints coincide with studs. Horizontal board joints are fi tted with an

internal 100mm wide x 25mm PROMATECT® -250 (4) cover strip, fi xed both

sides of the joint with steel drywall screws at 250mm nominal centres.

4) 9.5mm thick DURASTEEL® sheet (3), fastened to the framework, through the

PROMATECT® -250 boards, on both sides of the wall using M5.5 steel self drill

and tapping Tek screws at 250mm nominal centres. The length of fi xing to be

suffi cient to ensure appropriate penetration of screw thread, in accordance with

recommendations from the fi xing manufacturer. Vertical joints coincide with the

studs. Horizontal board joints coincide with the horizontal channels or are fi tted

with an internal steel cover strip, 100mm wide x 3mm thick, fastened on both

sides of the joint with M5.5 steel self drill and tap Tek screws at 250mm

nominal centres.





2 x 12m – 15m 150mm x 60mm x 3mm thick 48 dB

The notation ‘2x’ refers to back-to back channels that are fastened together with M10

steel bolts and nuts at 500mm maximum centres. The vertical joints in the DURASTEEL®

panels must be offset by 30mm from the centreline of the back-to-back studs to avoid a

straight through path for hot gasses. The horizontal channels are single channels.



allowance is provided at the top of a partition, steel channels, minimum 50mm fl anges x

3mm thick, are fastened to the vertical channels with M10 steel bolts and nuts. The



with minimum two M10 bolts. At the junction below the expansion gap the channels are

connected, through slotted holes, with minimum two M10 bolts fi tted with fusible


with a DURASTEEL® and PROMATECT® -250 board cover panel that is fastened to the

steel framework above the gap (through the facing boards) and overlaps the facing boards

below the gap by at least 75mm.

27


DURASTEEL® COMPOSITE MEMBRANE SPECIFICATIONS

240 Minute DURASTEEL® Composite Membrane Plenum Ceiling -

Fire from Below (E240 EI60)

Introduction

This DURASTEEL® composite membrane plenum ceiling may be constructed as a self-

supporting membrane for areas up 3m x 2m (maximum span 3m); or as a suspended

ceiling system with hangers coincident with the longitudinal framing channels at

1500mm centres.

Promat PROMATECT® -250 panels, fi tted to underside of the DURASTEEL® ceiling,

contribute to the fi re insulation performance of the system, and also provide a fair face

to the ceiling.

Construction

Self Supporting Ceiling Option: Weight (nominal) 37kg/m2

The maximum area as a self supporting ceiling (supported on all four edges) is 3m x 2m.

Perimeter framing (1) of 80mm x 60mm x 3mm CRC is fastened to surrounding

construction with M10 or M12 all-steel expanding anchors (or equivalent for alternative

types of supporting construction), at 500mm maximum centres.

Supporting channels (2) in 80mm x 60mm x 3mm CRC at 1200mm maximum

centres are either welded to the perimeter framing or joined using 120 x 60 x 3mm

angled cleats fastened to each channel member with two M10 steel bolts and

nuts. Transverse 80mm x 60mm x 3mm CRC (3) are installed coincident with the

DURASTEEL® end of board joints.

9.5mm DURASTEEL® (4) is fastened to the underside of the framing using 38mm TEK

screws fi xed at 200mm centres.

MF5 ceiling sections (5) are installed perpendicular to the DURASTEEL® framing at

625mm centres, with MF6 (6) channel at the ceiling perimeter fastened to the walls.

The MF5 grid system is fastened to the CRC framework through the DURASTEEL®

panels, and to the underside of DURASTEEL® ceiling using 38mm TEK screws at

400mm centres.

A 15mm PROMATECT® -250 ceiling lining (7) is fastened to the MF grid system using

32mm Drywall screws at 200mm centres. (Screws are to be inserted 15mm from the

board edge, and 40mm from the corner of the board).

Note: PROMATECT® -250 boards are installed parallel to the DURASTEEL® panels

(and at right angles to the MF5 ceiling sections), but with staggered joints in both

directions between layers.

100mm wide PROMATECT® -250 cover strips (8) are fastened behind the transverse

joints between the MF5 sections of the PROMATECT® -250 boards, using 32mm

drywall screws at nominal 250mm centres, with the screws at 25mm from edge of the

board, and 50mm from ends of the cover strips.

Suspended Ceiling Option: Weight (nominal): 37kg/m2

Perimeter framing of 80mm x 60mm x 3mm CRC (1) is fastened to surrounding

construction with M10 or M12 all-steel expanding anchors (or equivalent for alternative

types of supporting construction) at 500mm maximum centres.

Primary channels of 80mm x 60mm x 3mm CRC (2) at 1200mm maximum centres

fastened to the perimeter and suspended from the building structure above the ceiling

membrane using steel drop rods at maximum 1.5m centres. The threaded rods pass

through clearance holes in the upper fl ange of the channels, and are fastened with steel

hexagon full nuts.

The diameter of the hanger rods are such sized so that the tensile stress within the rods

does not exceed 6N/mm2.

An expansion allowance of at least 6mm per metre is required for primary channels

longer than 4m.


channels (minimum 50mm fl anges x 3mm thick) are fastened to the primary channels

with M10 steel bolts and nuts. The width of the jointing channel (web dimensions) should

be such that it is a close fi t within the primary channels.

On one side of the expansion gap the primary and jointing channels are connected with

minimum two M10 bolts. On the opposite side the channels are connected, through

slotted holes, with minimum two M10 bolts fi tted with fusible washers.

Transverse 80mm x 60mm x 3mm CRC (3) are cleated between the primary channels,

coincident with the DURASTEEL® board ends.

9.5mm DURASTEEL® (4) is fastened to the underside of the framing using 38mm TEK

screws fi xed at 200mm centres.

MF5 ceiling sections (5) are installed perpendicular to the DURASTEEL® framing at

625mm centres, with MF6 (6) channel at the ceiling perimeter fastened to the walls.

The MF5 grid system is fastened to the CRC framework through the DURASTEEL®

panels, and to the underside of DURASTEEL® ceiling using 38mm TEK screws at

400mm centres.

A 15mm PROMATECT® -250 ceiling lining (7) is fastened to the MF grid system using

32mm Drywall screws at 200mm centres. (Screws are to be inserted 15mm from the

board edge, and 40mm from the corner of the board).

Note: PROMATECT® -250 boards are installed parallel to the DURASTEEL® panels

(and at right angles to the MF5 ceiling sections), but with staggered joints in both directions

between layers.

100mm wide PROMATECT® -250 cover strips (8) are fastened behind the transverse joints

between the MF5 sections of the PROMATECT® -250 boards, using 32mm drywall screws at

nominal 250mm centres, with the screws at 25mm from edge of the board, and 50mm from

ends of the cover strips.

Since drop-rods support the ceiling, the length and width of ceiling membrane

is unrestricted.


28



Heathrow Terminal 5The quality of Promat DURASTEEL® and our specialist installers were tested to the full during the construction of Heathrow Terminal 5. Promat supplied 100,000m2 of DURASTEEL® to the £4.2m billion project, its largest specifi cation to date.

Designed by the Richard Rogers Partnership, T5 is being hailed as a new landmark for London. It can accommodate 30 million passengers a year. But there’s far more to it than just a building. As well as the vast new terminal – which could fi t 50 football pitches – and its two satellites, the project includes 47 aircraft stands, a control tower, a 4,000 space multi-storey car park, a hotel, rail links, a spur road from the M25, even a diversion of two rivers.

Promat’s input includes the largest ever specifi cation of a DURASTEEL® fi re barrier. It is being used in the main terminal building, the satellites and in the railway station – in some areas forming barriers 14m high.

Promat supplied the 100,000m2 of DURASTEEL® in 9.5mm sheet for insulated fi re barriers. It features prominently below apron level, lining the tunnel-like service corridors, the cavernous baggage handling areas, lift pits, workshops and plant rooms. The continuous barriers of silver Promat DURASTEEL®, punctuated by apertures for doors and services, provides a purposeful presence throughout all these areas.

Promat DURASTEEL® easily met the specifi cation for EI 120 fi re resistance. But that’s not the only reason it was chosen. The system was installed well before the dry envelope stage, so it had to be exceptionally tough and durable.

MACE Solutions – the fi xed price service provider within Mace Infrastructure Sector – are the package contractor responsible for the design and construction of the compartment walls below the main terminal.

And the architects working in partnership with MACE Solutions, Bryden Wood Associates, cite Promat’s technical expertise in helping to develop the specifi cation, including wind loadings for the tall barriers and developing systems such as barriers with a plasterboard facing for offi ce areas.

The Promat DURASTEEL® barriers’ high impact resistance was another key factor. “The barriers must withstand the impact of trolleys and baggage systems,” says project architect Dan Cunliffe. “Promat DURASTEEL® was the best product for the project, based on its versatility across a wide range of performance and other functional criteria.”

The Promat DURASTEEL® walls were constructed from pre-cut kits fabricated in R&S Fire & Security Limited’s factory in Essex, and delivered in meticulously labeled, pre-assembled kit form. They are installed section by section using scissor lifts.

John Allsop, the senior site agent for R&S, says “Promat DURASTEEL® is as easy to install as plasterboard, but of course it’s far more durable and robust.”

“We have a close association with both Promat and MACE Solutions,” says R&S Group’s managing director Keith Barclay. “This proactive relationship has ensured that delivery of the contract has run smoothly and effi ciently for the client BAA. It’s on time, within budget and in accordance with the T5 project principles.”

CASE STUDIES

“ Before the roof went on,

rain water was running

down the DURASTEEL®

walls for months on end

without any detrimental

effect on the integrity

of the product.”

says John Allsop,

site agent for Essex-based R&S

Fire & Security Ltd, the specialist

sub-contractor responsible for

its installation.

“ The system selection

process identifi ed Promat

DURASTEEL® as the most

appropriate partitioning

material based on the fi re

rating, its durability and

ability to withstand the

environmental conditions

that exist during the early

phases of construction”

MACE solutions

29


White City Development, West LondonThe tallest ever DURASTEEL® fi rewall in the UK is providing protection for power plants within the refurbished Grade ll-listed west DIMCO building, a central component of the regeneration.

Westfi eld London is a retail, leisure and lifestyle development by the world’s largest retail property group, Australian-owned Westfi eld. The development is a 46-acre site between Shepherd’s Bush and White City tube stations, until recently an industrial wasteland. The £1.6 billion development contains the largest shopping centre in Europe along with leisure facilities, 14-screen cinema, a spa and gymnasium, bars, restaurants, new transport links and affordable housing. Westfi eld London aims to become the capital’s premier retail, leisure and lifestyle destination.

On Westfi eld London, Promat DURASTEEL® came through with fl ying colours. The Grade II-listed DIMCO building was built more than 100 years ago, originally to house Europe’s fi rst electricity generating facility. Its refurbishment has been an ambitious and complex task involving extensive temporary works for the complete roof and roof structure replacement. A Promat DURASTEEL® barrier provides 120 minutes fi re compartmentation protection for the electricity sub-station within the west DIMCO structure, which supplies power to the new development.

At 25m high, the barrier installed is the tallest to date, and one of the most complex in terms of detailing and installation. Promat’s expertise was key.

London based Towns-Wadey is Westfi eld’s building contractor for the DIMCO project. Design Manager James Wraight said: “The DURASTEEL® wall has a bespoke design which is completely independent from the listed DIMCO building fabric, new roof and roof structure, offering 2 hour fi re compartmentation and fi re protection to the supporting steel structure. To keep the wall independent, we worked closely with Promat, specialist contractor Sharpfi bre and the Architect to achieve working movement details whilst maintaining a practical and safe installation process. We were able to use the system to hide the complex supporting steel structure, eliminating further fi re protection providing value engineering options for our client”.

“DURASTEEL® was the right product for the job and Promat offered good design advice,” says Sharpfi bre.


30

So why Promat

DURASTEEL®?

“ It’s a very versatile

material, offering a high

level of fi re protection...

...The fi re barrier

comes as a complete

system, so you don’t

need to specify an

additional fi re stopping

material for services

penetrations. The

contemporary aesthetic

of the DURASTEEL®

complements the

industrial character of

the DIMCO building.”

Lisa Pemberton, project architect

for Ian Ritchie Architects.



TESTIMONIALS

31

THE INVICTA GROUP

“Over a period of 10 years, Invicta

Storage Systems Ltd has been

pleased to install DURASTEEL®

barriers and vaults to our clients,

resulting in an excellent working

partnership with Promat UK Ltd.

Invicta values its position as a licensed

installer and actively takes every

opportunity to advance its technical

sales, product knowledge and

market share.

DURASTEEL® has become one of our

core products and we have successfully

installed a number of 4-hour fi re rated

barriers and vaults to many of our blue

chip clients throughout the UK, Europe

and the USA.

Our success has been contributed

to referrals from satisfi ed customers,

impressed by the product’s unique

capabilities and our professional service.

We look forward to building on an already

excellent working relationship with

Promat in the future.”

MITIE McCARTNEY FIRE

PROTECTION LIMITED

“MITIE McCartney Fire Protection Ltd, part

of the £1.4 billion pound, 50,000 strong

MITIE Group Plc, have been a market

leader in passive fi re protection for over

25 years. For most of this time, we have

been working closely with Promat, utilising

their full range of products, services and

technical support.

Appointed as a licensed DURASTEEL®

applicator for fi re barriers at the inception

of the scheme, MITIE McCartney Fire

Protection and Promat are capable of

bringing together their vast experience to

provide and enhance life safety systems

and property protection on sites as varied

as airports, steel works, commercial

premises and power stations.

DURASTEEL® has proved popular with

clients, not only because of its robust

nature but also due to the confi dence it

provides through the extensive test data

and certainty of application through the

approved licensed installer scheme.”

R&S FIRE AND SECURITY LIMITED

“In 1998 we created a separate division within

the R&S group devoted solely to DURASTEEL®

Systems. We take pride in the quality of our

installations and strive to improve our technical

capabilities in order to provide our Clients’

with both the service they seek, and a product

system that fulfi ls their needs.

Over this period we have formed an excellent

working relationship with Promat UK Ltd in both

promoting, and successfully manufacturing

and installing 4 hour fi re rated barrier, ceiling,

enclosure, and ductwork systems for our blue

chip clients throughout the UK, Europe

and Asia.

Our professional attention to design, detail and

installation of these fl exible and unique systems by

a dedicated labour force and management team,

has enabled this division to succeed. This coupled

with our “can do” approach has resulted in repeat

business and referrals from satisfi ed Clients.

In continuing partnership with Promat UK Ltd,

we anticipate successfully expanding on this

relationship to provide more clients with the

proven and tested Promat DURASTEEL® system

to solve their fi re protection problems.”

SHARPFIBRE LIMITED

“At Sharpfi bre our mission is to safely deliver high quality fi re protection

and insulation solutions that are cost effective for our clients and

profi table for both the company and its stakeholders. Established since

1987 Sharpfi bre has become a leader in passive fi re protection and are

pleased to be a licensed DURASTEEL® installer.

Operating out of our offi ces in Basildon, Essex and Paris in France,

Sharpfi bre have built an excellent reputation for being the contractor of

choice when it comes to technical knowledge, directly employed labour

and health and safety. Working closely with Promat and our other key

supply chain partners, Sharpfi bre provide a cost-effective, effi cient

and technically compatible fi re protection solutions available on the

market today.

Having completed several major DURASTEEL® schemes, including the

tallest ever DURASTEEL® fi rewall in the UK, it is now that we can bring

to our clients the knowledge and experience of both a market leading

installer and a market leading manufacturing team.”


Promat UK LimitedThe Sterling Centre, Eastern Road, Bracknell, Berkshire RG12 2TD

Telephone: 01344 381300 Fax: 01344 381301www.promat-durasteel.co.uk

DSB Sept.08


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Durasteel brochure v24