Durasteel projects ref

Durasteel Valve Enclosures ensure safe operational access at chemical storage facility

Location: Dubai, UAE

Image Gallery Below

DOW Chemical Company's chemical storage facility in Dubai recently identified a safety

requirement to protect the main deluge valves within a chemical storage area from

potential fire and explosions. The valves were located in an open and exposed area

adjacent to the main chemical storage facility.

Tasked with designing 3-sided Durasteel barriers which had to be completely free-

standing, wind resistant and weather-proof, and maintain their integrity within

potentially harsh chemical atmospheric conditions.

Our solution was to build free-standing Durasteel valve protection enclosures

constructed from 80mm x 60mm x 3mm steel channels with a single sheet of Durasteel

bolted to the exterior surface.

Each enclosure was completely installed within 1.5 days from start to finish and now

provides the valves with the blast and fire protection required to ensure continued and

safe operational access in the event of a fire or explosion.

Site supervisor, Louie Aguilar, commented "it was a very fast installation, completed

incredibly quickly by a very professional team and we are extremely pleased with the

outcome."

Gallery

Fire Barriers installed in underground tunnels at Jebel Ali Desalination Plant

Location: Dubai, UAE

Image Gallery Below

The world's largest desalination plant, the Dubai Electricity and Water Authority (DEWA)

Jebel Ali Desalination Plant located in Dubai, which has an electrical capacity of

2,000MW and purifies around 480 million litres of seawater daily, has recently had

Durasteel extensively installed across the facility by our Middle East division.

Underground tunnels and cable routes run across the entire desalination site,

connecting various buildings at below-ground level and housing cables vital to the

operation of the plant. In order to isolate these tunnels and buildings from any potential

fire hazards, site consultant, Fichtner Consulting Engineers, and main site contractor,

Doosan Heavy Industries and Construction, decided that fire barriers were an essential

requirement in the tunnels in order to maximise safety, contain the spread of fire and

limit the damage caused in the event of a fire occurring.

The requirement was to construct fire barriers to provide effective compartmentation in

the following typical locations:

• Between building basements and cable trenches/tunnels

• Between cable trenches and cable tunnels

• Between trenches and escape routes (ladders) and exits

It was identified that fire barriers were required at 79 separate tunnel locations across

the site in order to effectively isolate a fire occurring within the tunnels, and that each

barrier must provide 2 hour fire protection and withstand high numbers of door

openings and closures every day, in addition to being fully demountable and

relocatable. The size of the fire barrier at each location was designed to be 2.80m wide x

2.20m high, with each fire barrier containing one 2 hour fire rated access door and cut-

out provisions for 6 cable trays on each side of the door to pass through the fire barrier,

with the penetrations being filled with firebat.

Working in harsh underground conditions and with extremely limited manoeuvring

space, each Durasteel barrier was installed in phases, with provisions for cable pulling

and fixing of the access fire doors at a later stage. Erection of each complete barrier,

including the fire doors and penetration sealing, took less than 2 working days from

start to finish.

With the project deemed a success, Durasteel was then specified for use on the same

site as removable generator barriers.

Gallery

Durasteel Ceilings and Cable Turning Box Protect EDF Substation

Location: London, UK

Image Gallery Below

Throgmorton Street in London is a commercial retail outlet which has recently

undergone a complete refurbishment and an EDF substation installed into the basement

area.

Invicta's Durasteel division were asked to design and install a Durasteel 4 hour fire rated

cable turning box complete with demountable panels to allow access by EDF engineers,

with blastproof fire morter on all penetrations.

Additionally, Invicta also designed and installed 2 independent Durasteel 4 hour fire

rated ceilings to the substation and switch rooms in the basement to protect the offices

above from any explosions originating from the high voltage cables and transformers

located in the rooms. The ceilings were approximately 12m² and 25m² in size and

included a rake detail to deflect any blast out through the louvre in each room.

The entire project was installed from start to finish in 3 weeks.

Related pages: Fireproof Ceilings, Substation Ceiling Fire Protection

Gallery

Demountable EDF Energy Transformer Blast Barriers


Image Gallery Below

Invicta's Durasteel division has recently completed the installation of 4 demountable

EDF Energy blast barriers to give blast protection of up to 10kN/m² at a substation

demolition site in London.

Due to the limited working space on site, the 4 2.5 tonne Durasteel blast barriers were

fully pre-fabricated and then lifted and secured into position using a crane. The blast

barriers were designed and installed to protect personnel working on the demolition

site from the potential explosions of 4 transformers located in the immediate vicinity.

The barriers are fully demountable within 4 hours in the event of a transformer failing

and the barrier requiring removal in order to allow access to the transformer.

The project was completed from start to finish in less than 5 weeks and the blast

barriers comply with stringent EDF Energy specifications.

Related pages: Transformer Barriers, Blast Walls

Gallery

Transformer Blast Barriers provide blast protection to Fertiliser Plant

Location: UK

Image Gallery Below

Invicta has recently completed the design and installation of 3 self-supporting

transformer blast barriers at a fertiliser plant in the UK.

The 4.2m x 4.5m blast barriers were designed bespoke to provide 10kN/m² blast

protection, with welded steel bracing supports in order to provide the barriers with

increased stability to cater for the additional blast protection and wind loadings in the

area. The 3 blast barriers were installed in order to prevent a chain blast occurring

should one of the 4 transformers in the area explode.

Installation of all 3 blast barriers was completed in less than 3 weeks, much of which

took place in some of the most severe snow and ice conditions the UK has experienced

in the last century. However, with Invicta's vast experience in designing, project

managing and installing Durasteel, these conditions were overcome and the project was

completed on time.

Related pages: Transformer Barriers, Blast Protection

Gallery

Fireproof Vault Protects Council Records

Location: Staffordshire, UK

Image Gallery Below

Staffordshire County Council in the UK serves a population of around 800,000 residents

with vital services to the community, including schools, libraries, social services, trading

standards, highways and planning. With all of these services generating large numbers

of paper documents, the Council decided to relocate its document storage facility to a

new, larger warehouse and within it include a fireproof vault for the storage of the most

important documents.

Invicta were asked to design and install a 35m long x 7m wide x 5m tall vault, filled to

capacity with mobile shelving to maximise the vault's storage space. The vault was

engineered and designed to be completely self-supporting, without any internal or

external structural support columns and beams that would normally also require fire

protecting.

Providing industry leading 4 hour fire protection, the vault had air conditioning and a

water leak detection system installed to ensure complete protection from not only fire

but also moisture and water that could also potentially damage the documents inside.

A mantrap lobby was constructed on the outside of the vault's main entry door to

ensure that the ideal ambient temperature could be constantly maintained inside the

vault even when doors were opened. All entry doors were secured with magnetic lock

PIN entry systems to prevent unauthorised access to the vault and sensitive documents.

The vault installation was completed in under 8 weeks before the remaining space in the

warehouse was filled with pallet racking for the storage of the Council's non-sensitive

documents.

Related pages: Fireproof Vault

Gallery

Crown Records Management install custom designed Durasteel fireproof vault


Image Gallery Below

The backing up of business-critical data is widely regarded as being one of the most

important processes a business can do and is a fundamental element of any business

continuity plan. Yet research suggests that up to 75% of backup tapes are kept on-site,

meaning that in the event of a disaster, any business continuity plan that may be in

place will be rendered useless. On average, by the 6th day of a major data loss,

companies experience a 25% loss in daily revenue, and by day 25, this increases to 40%.

It is also estimated that 43% of companies that experience a severe data loss disaster

never re-open.

In response to increasing customer demands driven by the recent surge in both natural

disasters and man-made threats around the world, Crown Records Management

decided to have a custom designed Invicta Durasteel vault installed at one of their

records storage facilities in the UK, providing clients with an industry-leading 4 hour fire

protected facility for the secure storage of their business-critical data tapes and

irreplaceable documents.

The challenge faced by Invicta was to design and integrate the media and document

vault within a large multi-tier racking system without compromising on any loss of space

utilisation within the cube of Crown's building. Invicta's solution was to build a 630

square metre, 4-tier Durasteel vault in one corner of the warehouse to a height of 12

metres. Durasteel is a 4 hour fire rated product that has been tested extensively in the

UK to comply to all relevant parts of BS 476, as well as many international standards

such as Factory Mutual (FM), Underwriters Laboratories Inc (UL), Underwriters

Laboratories Canada (ULC), Det Norske Veritas (DNV), Lloyds Register of Shipping (LRS),

Zulassung, EDF and LUL. In addition to providing superior protection from fire, Durasteel

also provides impact and moisture protection, both of which are essential, but often

overlooked, features for vaults located within buildings surrounded by other structures

that may fall onto it and building services that may fail in the event of a disaster.

Durasteel has also achieved the stringent Certifire approvals and was therefore installed

on the underside of each level of the vault to provide an independent 4 hour fire rated

compartment to each floor level. Mobile shelving was installed on the ground floor,

specifically designed for the optimal storage of over 27,000 data tapes, whilst the upper

three levels of the vault were equipped with racking for the secure storage of over 6000

boxes.

Crown's vault was completed with state-of-the-art climate control and gas suppression

systems in order to regulate a constant environment, and was then smoke and pressure

tested in order to certify its performance.

Related pages: Fireproof Vaults

Gallery

Durasteel Suspended Ceiling Membrane E240 (Fire from Above

and Below)

• Fire resistance: 240 minutes integrity only (Fire attack from above or below)

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

• Overall depth: 89.5mm

• Weight (nominal): 27kg/m2

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 flange 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 fire ratings up to 240 minutes. (This may be increased to 10N/mm

2 if only a

120 minutes fire rating is required).

9.5mm Durasteel boards fastened to lower flange 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 fixing to be sufficient 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 member with two M10 steel bolts and nuts.

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

channels, minimum 50mm flanges 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 fit 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 fitted with fusible washers.

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

required for primary channels longer than 4m.

For fire 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.

Durasteel Suspended Ceiling Membrane E240 EI120 (fire from

below)

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• Fire resistance: 240 minutes integrity � 120 minutes insulation (Fire attack from

below)


• Overall depth: 108.5mm



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





hexagon full nuts.


6N/mm2 for fire ratings up to 240 minutes. (This may be increased to 10N/mm

2 if only a

120 minutes fire rating is required).

9.5mm Durasteel fillet strips fitted 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 fillet strips) to lower flange 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 fixing to be sufficient 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 member with two M10 steel bolts and nuts.

Rock wool insulation 80mm x 140 kg/m3 nominal density, fitted over the soffit layer of

Durasteel by filling 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 Suspended Ceiling Membrane EI120 (fire from above

or below)


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


• Overall depth: 166mm








hexagon full nuts.


10N/mm2.

6 mm Durasteel boards fastened to lower flange of steel channels with M5.5 steel self-




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.











required for all sizes of ceiling.


unrestricted.


or below - method 1)


• Fire resistance: 240 minutes integrity & insulation. (Fire attack from above or

below)





or M12 allsteel expanding anchors (or equivalent for alternative types of supporting





hexagon full nuts.


6N/mm2 for fire ratings up to 240 minutes.

9.5mm Durasteel boards fastened to lower flange of steel channels with M5.5 steel self-




manufacturer's recommendations.


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, total of 120mm x 140 kg/m3 nominal density fitted with 2 x 60mm

thick layers, one layer fitted over the Durasteel soffit layer by filling the channels and

the second layer fitted 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. Where

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

minimum 50mm flanges 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 fit within the primary channels.



slotted holes, with minimum two M10 bolts fitted with fusible washers. For fire attack

from below, an expansion allowance of at least 6mm per metre is required for primary

channels longer than 4m.




unrestricted.


or below - method 2)


• Fire resistance: 240 minutes integrity & insulation. (Fire attack from above or

below)

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









hexagon full nuts.


6N/mm2 for fire ratings up to 240 minutes.

9.5mm Durasteel fillet strips fitted 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 fillet strips) to upper and lower flange 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 fixing to be sufficient to ensure appropriate penetration of screw thread in



by steel channel the same size as the primary channels.




Rock wool insulation 150mm x 140 kg/m3 nominal density, fitted over the soffit layer of

Durasteel by filling the channels. Joints in layers of rock wool overlap by at least 150mm.







slotted holes, with minimum two M10 bolts fitted with fusible washers. For fire attack

from below, an expansion allowance of at least 6mm per metre is required for primary

channels longer than 4m.




unrestricted.

Durasteel Composite Membrane Plenum Ceiling E240 EI60 (Fire

from Below)


Introduction

This Durasteel composite membrane plenum ceiling may be constructed as a

selfsupporting 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, fitted to underside of the Durasteel ceiling, contribute to

the fire 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

fixed 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






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

fixed 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.

Durasteel DD120 and DD240 Fire Shutters


Leaf

• Overall Thickness: 12mm (DD120) 28mm (DD240)

• Material: 9.5mm thick Durasteel sheet

• Jointing Construction: Mitred and Welded

Frame

• Overall Frame Depth: 80mm

• Material: 45 x 80 x 45 x 6mm thick Z-section/25 x 15 x 3mm thick angle section

• Jointing: Mitred and Welded joints

• Type and Configuration: 3-sided frame with trailing edge flame trap

Finish

• Frame and Leaf: Standard shop applied zinc based primer, ready for site painting

(P3)

Ironmongery

• Standard weight counterbalance system, heavy duty mild steel track

Certification

• BS 476: Part 22: 1987

Dimensional Details Ref Single Leaf Doorset Example Calculation

Structural opening width A A 920mm

Structural opening height B B 900mm

Overall frame width C (A + 92 = C) 1012mm

Overall frame length D (B + 96 = D) 996mm

Door leaf width E ((B + D + 92 = E) 1988mm

Door leaf height F (A + 178 = F) 1098mm

Durasteel Fire Barrier E240 Integrity Only


• 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


• 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



A single layer of 9.5mm Durasteel fixed 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 fixing to be sufficient to


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 us

for further information.

Steel channel sizes for barrier heights up to 15 metres

Height of Barrier (m) Channel size (mm x mm x mm) Estimated Sound Insulation Rw (dB)

0 - 6 80 x 60 x 3 33

6 - 9 150 x 60 x 3 33

9 - 12 Two 150 x 60 x 3 Back to back 33

12 - 15 Two 175 x 60 x 3 back to back 33

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.

Durasteel Fire Barrier E240 EI60


• 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 fillet fixed on both sides of channel. Fillet strips to overlap channel by

minimum of 20mm on both sides.

9.5mm Durasteel sheets fixed through fillet 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 fixing to be sufficient to ensure appropriate penetration of screw thread in


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.

Steel Channel sizes for barrier heights up to 15 metres

Height of

Barrier

Channel size (mm x

mm x mm)

Durasteel fillets

per face

Rock Wool

infill

Estimated sound

Insulation Row

0 - 6 80 x 60 x 3 1 None 42

6 - 9 150 x 60 x 3 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





Durasteel Fire Barrier E240 EI120



either face)













9.5mm Durasteel fillet strips fixed on both sides of channel, number of fillet strips

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

of 20mm on both sides. 9.5mm Durasteel sheets fixed through the fillet 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 fixing to be sufficient 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 infill, according to the table below, is fitted into the channels. The

layers are staggered by a minimum of 150mm.

If the rock wool does not fill 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.


Height of

Barrier

Channel size (mm x

mm x mm)

Durasteel fillets

per face Rock Wool infill

Estimated sound

Insulation Row

0 - 6 80 x 60 x 3 1 2 x 40mm x

140kg/m3

47

6 - 9 150 x 60 x 3 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

53

12 - 15 Two 200 x 60 x 3

back to back None

4 x 50mm x

60kg/m3

53





Durasteel Fire Barrier EI240



either face)


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











9.5mm Durasteel fillets fixed on both sides of channel, number of fillet strips according

to requirements in Table below. Fillet strips to overlap channel by minimum of 20mm on

both sides.

9.5mm Durasteel sheets fixed through the fillet 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 fixing

to be sufficient 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.

Rockwool infill, according to the table below, is fitted into the channels. The layers are

staggered by a minimum of 150mm. If the rock wool does not fill 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.


Height of

Barrier

Channel size (mm x

mm x mm)

Durasteel fillets

per face Rock Wool infill

Estimated sound

Insulation Row

0 - 6 80 x 60 x 3 2 3 x 40mm x

140kg/m3

50

6 - 9 150 x 60 x 3 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





Typical Connection Details


Please note that the following Durasteel system connection details are examples only.

Connection details for each system will differ according to the specific requirements of

the system.

Wall Interface

1. 150mm x 60mm x 3mm CRC Frame

2. M10 Expanding Bolts at 500mm Maximum Centres

3. 15mm Promatect 250

4. 9.5mm Durasteel Sheet

5. Tek Screws at 200mm Maximum Centres

6. Silicone to all Abutments

Sheet Join Interface

1. 150mm x 60mm x 3mm CRC Frame Back To Back

2. M10 x 25mm Bolts c/w Nut and Washer




Building Steel Penetration Interface



3. 9.5mm Durasteel Sheet (2nd layer)

4. Existing Steelwork with Minimum 12mm Sealant Around Steelwork



Pipe Penetration Interface





5. Existing Pipe

6. Rockwool Insulation

7. Promaseal Fire Compound

8. 100mm x 50mm x 3mm Rolled Steel Angle

Cleating - Corner Interface Elevation View



3. M10 x 25mm Hex HD Bolts or M10 x 20mm CSK HD Bolts c/w Nut and Washer

4. 120mm x 60mm x 3mm Angle Cleats

5. M10 x 20mm CSK HD Bolts c/w Nut and Washer

Cleating - Perimeter Interface Elevation View




4. 2 No. 120mm x 60mm x 3mm Angle Cleats


Cleating - Section View




4. 2 No. 120mm x 60mm x 3mm Angle Cleats


Cleating - Internal Interface Elevation View



3. 120mm x 60mm x 3mm Angle Cleat



Cleating - Internal Interface Section View



3. 120mm x 60mm x 3mm Angle Cleat




Suspended Movement Head Detail

1. Profile Cut and Seal to Purlins

2. Curved 150mm x 60mm x 3mm CRC Head Channel





7. Slotted Cleat for 80mm x 60mm x 3mm CRC Frame

Standard Movement Head Detail

1. Profile Cut and Seal to Purlins

2. Curved 200mm x 60mm x 3mm CRC Head Channel





7. Slotted Cleat for 150mm x 60mm x 3mm CRC Frame

Wall Fixing

1. Dwarf Wall

2. Existing Plasterboard Wall

3. Mastic

4. Mastic






Roller Shutter Steelwork Fixing

1. 50mm x 50mm x 3mm Angle






7. Welded Plate Between Flanges

8. Mastic

Business

Durasteel projects ref