FireMaster Cement Systems For Steel Floating Floors · ℡ +44 (0)151 334 4030 Reference FM-MS 01 CF Rev 0 Fire Protection Systems Information Release Date June 2010 METHOD STATEMENT

Page 1 of 11 Thermal Ceramics Tebay Rd.,

Bromborough, CH62 3PH. England www.thermalceramics.com

www.thermal-ceramics-firemaster.co.uk ℡ +44 (0)151 334 4030

Reference FM-MS 01 CF Rev 0

Fire Protection Systems Information

Release Date

June 2010

METHOD STATEMENT

FireMaster Cement Systems For Steel Floating Floors

CONTENTS

1. System Components 2. Installation Sequence 3. Installation Guidelines for FireMaster FireBarrier 135






Release Date

June 2010

1. System Components The system comprises a stiffened steel deck of “A” class construction with a fire insulation system applied on the non-fire side. The un-insulated, stiffened, side of the deck is exposed to the fire. The system components are shown in the diagram below

Drawing FM CAD09-4.96bFloating Floor Components

FIRE

FireMaster Fire Barrier 135 Th: 20mm dens: 1050 kg/m3

Anchoring: Welded pinspins distance 450mm

Fiber glass net (5x5mm)W: 75 g/mq

Steel net (50x50mm)Ø 1,7mm w: 725 g/mq

Primer Silacoll 100W: 200 g/mq

Thermo-E-glass woven fabric with aluminium foil coumpound W:210g/mq

FireMaster paper 607Th: 5mm dens: 210 kg/m3

Component Supplier Details CD welded mild steel anchors and 20mm minimum diameter friction fit washers

Any suitable supplier 3mm diameter length minimum of 40mm

Primer Applied to deck surface

Van Baerle Silacol 801800

FireMaster 607 Paper applied over primer

Thermal Ceramics 5mm thick

Glass Fibre applied over FireMaster Paper

HKO Isolier und Textiltechnik GmbH

Thermo E-Glass woven fabric 210 g/m3 faced with aluminium foil

Galvanised Steel Mesh applied over glass fibre fabric and retained with anchor washer

Any suitable supplier 50mm x 50mm mesh 1.7mm gauge 725 g/m2 weight

FireBarrier 135 floor lining Thermal Ceramics 20mm thick density 1050 kg/m3

Glass Fibre netting installed in centre of FireBarrier 135 lining

Any suitable supplier 5mm x 5mm mesh 75 g/m2 weight






Release Date

June 2010

2. Installation Sequence 2.1. Surface Preparation

Ensure that the surface of the steel deck is clean and dry.

2.2. Installation of anchors

The anchors are welded using standard CD welding procedure and in the pattern shown in the system drawing.

2.3 Installation of Silacol primer

The primer is installed by spatula or trowel to achieve a covering of approximately 200 g/m2 .

2.4. Installation of FireMaster Paper

FireMaster Paper is installed over the primer by gluing. Joints between adjacent layers are butted tightly together.






Release Date

June 2010

2.5 Installation of Thermo E-Glass woven fabric

The fabric is installed with the aluminised face downwards and with joints overlapped by a minimum of 10mm.

2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18






Release Date

June 2010

2.6 Installation of Mesh and Washers The mesh is installed by butt-jointing adjacent sheets and then held in place using friction fit washers installed onto the anchor pins at the corners of the mesh quadrant (see picture). The purpose of the washer is to retain the cloth and avoid movement of the mesh during spray application of the FireBarrier lining. Any excess pin length should be cropped before installing the FireBarrier 135.

2.7 Installation of FireBarrier 135 FireBarrier 135 is sprayed into place in two applications of 10mm thickness. After the first 10mm is installed the glass fibre net is placed over the wet surface and the remaining 10mm thickness of FireBarrier is installed over the net.






Release Date

June 2010

Spaying of the FireBarrier 135 is in accordance with the standard techniques listed in Section 3. Although it is possible to obtain a high-quality, flat, surface by trowelling the surface after spraying the FireBarrier; this is not required as the final floor finish is applied afterwards. A slightly rough surface acts as a “key” for the floor bonding agent.






Release Date

June 2010

3 Installation of FireBarrier 135

3.1 Spray Equipment FireBarrier 135 is supplied to site as a dry powder in standard sized or extra-large bags (refer to the product data sheet for weight and packaging details). It is mixed with water in a spray machine and the wet mix is them pumped through tubing to a spray nozzle where it is mixed with compressed air at the exit of the nozzle and sprayed into place. Spray equipment known to work well as applicators are:

• PUTZMEISTER PFT G4/G5 • MTEC DUOMIX • MAIPUMP INTERNATIONAL M 200

Other pumps may also be used if demonstrated to be acceptable by Thermal Ceramics after a trial installation. The pump must have a mixing chamber in order to allow the complete mixing of FireBarrier 135 with the correct quantity of water before the wet mix is pumped through the applicator tube. 3.2 Set up of the spraying equipment First, ensure the spray machine is set up to deliver the correct consistency of FireBarrier 135. Different spray machines may require different ratios of water to FireBarrier 135 powder. The correct settings are governed by the viscosity of the wet mix as measured using a “Vicat” floating needle penetrometer. As a guide for setting up the spray machine, the average water to FireBarrier 135 powder ratio is 53.3% (by weight) and 0% minimum, 56.7% maximum. 3.3 Using the Penetrometer Take a sample of wet mix from the spray machine and fill a container to a minimum thickness

of 60mm. Ensure that the surface of the FireBarrier 135 in the container is flat. Place the penetrometer on the surface and unlock the floating needle so that it can penetrate into the wet mix. Observe the distance that the needle has penetrated into the mix from the needle scale. The consistency of the sample is correct when the needle travels a distance of between 30 to 40mm into the sample when the weight is 110g and the diameter of the needle is 10.2mm.




The spray machine requires a constant supply of FireBarrier 135 and water. The required pump pressure is dependent on the distance between the spray machine and spraying nozzle and is about one bar per metre length of the connecting hose. The spray nozzle diameter should be a minimum of 14mm (16mm recommended). 3.4 Spray Application of FireBarrier 135 Once spraying has commenced the application of the lining shall be continuous until completed. Any break in spraying should be timed to coincide with completion of a complete section. It is important that FireBarrier 135 is gradually built up to the full lining thickness over a section at a time. When a break during installation of more than 10 to 15 minutes is expected to occur, the mixing section and hose must be completely cleaned with water to prevent setting of any material remaining in the spray machine pump or spray hose. Always check the consistency of the FireBarrier at the exit of the spray gun before commencing spraying. Consistency should also be checked after a break of more than 3 to 5 minutes. If the performance of the pump or nozzle deteriorates then the installation should be stopped and the equipment cleaned or repaired as necessary. Check the final thickness is correct every 400-500mm along the lining by using the steel float held at an angle of 90 degrees to the surface. Any small areas requiring more FireBarrier can be finished by applying the material using a trowel. 3.5 Curing of the FireBarrier 135 after spraying When water is added to concrete, hydration occurs accompanied by the generation of heat. The amount of heat generated is sufficient to release some moisture as well as steam thus preventing full hydration from taking place. To compensate for this moisture loss and to allow complete hydration and optimum strength of the lining to develop, a curing process is necessary for FireBarrier 135 linings. This consists of keeping the lining surface sufficiently damp and cool. During the curing operation the lining temperature shall be maintained between 10 and 32 ºC. In cold conditions the rate of evaporation is generally low therefore wet curing may not be necessary. In high temperature conditions the evaporation is generally high and wet curing is of great importance.

Reference FM 6.0 Rev 2


Release Date

June 2010




The curing process should start immediately after initial setting when the lining surface has set hard enough to permit impinging water spray on the lining surface and should proceed for at least 24 hours. If using a water jet, keep the nozzle at approximately 4 metres from the lining surface. Start the first application of water one hour after installing the segment of the lining to be cured. Re-apply a second application of water 30 minutes after the first application and finally a third application a further 30 minutes later. Repeat the application of water if the lining surface shows any sign of becoming dry. When the lining installation is carried out in open air the lining surface must be protected from exposure to direct sunlight until the curing operation has been completed.

Reference FM 6.0 Rev 2


Release Date

June 2010






Release Date

June 2010

3.6 Key Installation Design Data Quantity of FireBarrier 135 required per m² Approximately 12.5 kg/m² of FireBarrier 135

is required per cm of required installed thickness (inclusive of wastage which is minimal due to the high adhesion of the material during spraying)

Typical Wastage during spraying Less than 1% of material applied Required environmental conditions for application

Above 10 ºC & below 80% RH. FireBarrier 135 has been installed in temperatures up to 40 ºC

Health & Safety Requirements No special requirements. Neutral pH material. No hazardous classification. Normal “common sense” practices for handling dust would apply.

Maximum thickness that can be installed in one layer

Approximately 55mm based on overhead spraying

Maximum working time when wet (for trowelling & finishing)

Up to 20 minutes

Drying Time Approximately 1 hour Curing Time 24 hours for initial curing (See Section above

on curing procedures), fully cured within 1 week to 28 days

Application Rate Varies with thickness installed & application conditions/requirements. 12 to 15 m² per hour worked for typical lining thickness used in tunnels (40mm upwards). Up to 30 m² per hour for thinner linings.






Release Date

June 2010

SUPPORT DOCUMENTATION

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Documents

FireMaster Cement Systems For Steel Floating Floors · ℡ +44 (0)151 334 4030 Reference FM-MS 01 CF Rev 0 Fire Protection Systems Information Release Date June 2010 METHOD STATEMENT