EXPANSION PROJECT
EXPANSION PROJECT
CB&I CONTRACT NO. 166000
CB&I CONTRACT NO. 166000
Prepared By:
Prepared By:
Mechanical Engineering, Houston, TX
Mechanical Engineering, Houston, TX
Document No:
Document No:
166000-000-SP-MU10-0019
166000-000-SP-MU10-0019
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Approved
Approved
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By:
00 2244--MMaarr--0088 IISSSSUUEED D FFOOR R DDEESSIIGGNN TTAAAA KKRRSS KKRRSS 1
1 2255--JJuunn--0088 IISSSSUUEED D FFOOR R DDEESSIIGGNN TTAAAA SSAAAA IIAARR 2
2 2277--FFeebb--0099 IISSSSUUEED D FFOOR R DDEESSIIGGNN DDDD JJBB HHTT 3
3 2299--AApprr--0099 IISSSSUUEED D FFOOR R DDEESSIIGGNN DDDD JJBB HHTT 4
4 2299--JJuunn--1100 IISSSSUUEED D FFOOR R DDEESSIIGGNN DDDD JJBB KKDDBB 5
5 0077--OOcctt--1100 IISSSSUUEED D FFOOR R CCOONNSSTTRRUUCCTTIIOONN DDDD JJBB GGAADD 6
6 0077--JJaann--1111 ISSUED FOR CONSTRUCTIONISSUED FOR CONSTRUCTION Incorporated Client’s Comments Incorporated Client’s Comments
D
DDD//JJBBBB KKDDBB GGAADD 7
7 2299--JJuull--1111 IISSSSUUEED D FFOOR R CCOONNSSTTRRUUCCTTIIOONN
Included Pitt-Char Fireproofing per Client’s Included Pitt-Char Fireproofing per Client’s request
request
D
TABLE OF CONTENTS
TABLE OF CONTENTS
1.0
1.0
INTRO
INTRODUCT
DUCTION...
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1.1
1.1
Purp
Purpose
ose ...
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1.2
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Scop
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1.3
1.3
Sell
Seller
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2.0
2.0
REFE
REFERENC
RENCES...
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2.1
2.1
Int
Intern
ernati
ationa
onal
l Pro
Protec
tectiv
tive
e Coa
Coatin
ting
g /
/ A
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2.2
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3.0
3.0
DEFI
DEFINITI
NITIONS..
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3.1
3.1
Hazar
Hazardous
dous Equi
Equipmen
pment
t and
and Pipi
Piping
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3.2
3.2
Hazar
Hazardous
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3.3
3.3
Fire
Fire Prot
Protection
ection (Fir
(Fire
e ratin
rating)
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4.0
4.0
REQU
REQUIRE
IREMENT
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4.1
4.1
Exten
Extent
t of
of Firep
Fireproof
roofing..
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5.0
5.0
PAI
PAINTING
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6.0
6.0
MATE
MATERIAL...
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6.1
6.1
Con
Concre
crete o
te or Li
r Light
ghtwei
weight
ght Con
Concre
crete:
te: For
Form P
m Plac
laced M
ed Meth
ethod a
od and
nd Pne
Pneum
umati
atical
cally
ly
Applied
Applied ...7
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6.2
6.2
Ligh
Lightweig
tweight
ht Cemen
Cementitio
titious
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Products
ucts...
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6.3
6.3
Int
Intume
umesce
scent M
nt Masti
astic (S
c (See A
ee Appe
ppendi
ndix A
x A and
and B fo
B for Ma
r Mater
terial
ial Req
Requir
uireme
ements
nts)) ...
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6.4
6.4
Reinf
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6.5
6.5
Water
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7.0
7.0
INSTA
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7.1
7.1
Concr
Concrete
ete Firep
Fireproofi
roofing
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7.2
7.2
Ligh
Lightweig
tweight
ht Cemen
Cementitio
titious
us Firep
Fireproofi
roofing..
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7.3
7.3
Int
Intume
umesce
scent M
nt Mast
astic F
ic Fire
irepro
proofi
ofing (
ng (See
See A
Appe
ppendi
ndix A
x A and
and B fo
B for A
r Appl
pplica
icatio
tion
n
Requirements)...10
Requirements)...10
8.0
8.0
WORKMA
WORKMANSHI
NSHIP
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8.1
8.1
Prep
Preparatio
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8.2
8.2
Curi
Curing
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ATTACHMENTS...11
ATTACHMENTS...11
APPENDIX
APPENDIX A
A –
– APPLICA
APPLICATION
TION OF IN
OF INTUMESCENT
TUMESCENT FIREPROOF
FIREPROOFING
ING ...17
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APPLICATI
APPLICATION OF CHARTEK 1709...
ON OF CHARTEK 1709... 17
17
APPENDIX
APPENDIX B
B –
– APPLICA
APPLICATION
TION OF IN
OF INTUMESCENT
TUMESCENT FIREPROO
FIREPROOFING
FING ...33
...33
APPLICAT
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMP
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). ANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I ANDIT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE.
DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED OIT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. NLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FORREPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I.
ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINSTIT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
1
1..00 IINNTTRROODDUUCCTTIIOONN 1
1..11 PPuurrppoossee
The intent of this standard is to establish a guide for determining which structural steel supports The intent of this standard is to establish a guide for determining which structural steel supports and equipment supports should receive fire protection with the objectives of minimizing danger and equipment supports should receive fire protection with the objectives of minimizing danger to personnel fighting fire, spread of fire and damage to process equipment.
to personnel fighting fire, spread of fire and damage to process equipment. 1
1..22 SSccooppee
This specification together with the referenced engineering drawings covers the minimum This specification together with the referenced engineering drawings covers the minimum requirements for the materials and application of fireproofing for hazardous equipment, structural requirements for the materials and application of fireproofing for hazardous equipment, structural steel elements, power and instrument cables and control valves within fire hazardous areas of steel elements, power and instrument cables and control valves within fire hazardous areas of the plant.
the plant. 1.2.1
1.2.1 Fire Fire proofinproofing mateg material rial for strfor structurauctural steel steel membel members srs shall hall be Chbe Chartek artek 1709 1709 or Pior Pitt-Chartt-Char XP. Append
XP. Appendix A and Appendix Bix A and Appendix B are added to this specifiare added to this specification to cover requication to cover requirementsrements for applicati
for application ofon of both intumescboth intumescent fireproofient fireproofing.ng. 1.2
1.2.2.2 All stAll strucructuratural steel steel inclul includinding modug modulele stesteel shael shall recll receive ieive intuntumescmescent maent mastic fstic firepireprooroofingfing (See Appendix A and Appendix B).
(See Appendix A and Appendix B). 1.2
1.2.3.3 VesVessel sksel skirts anirts and saddd saddles shles shall be firall be firepreproofoofed with ned with normaormal weigl weight conht concrecrete.te. 1
1..33 SSeelllleer r RReessppoonnssiibbiilliittyy 1.3.1
1.3.1 Any cAny conflict onflict between between the rethe requiremequirements nts of thiof this sps specificaecification ation and rend related lated codescodes, stan, standards,dards, data sheets, drawings, requisition, etc., shall be referred to Purchaser for data sheets, drawings, requisition, etc., shall be referred to Purchaser for clarification/resolution.
clarification/resolution. 1.3
1.3.2.2 SupSuppliplier shaer shall not makll not make asse assumpumptiontions for infos for informatrmation noion not furnit furnisheshed by Purchd by Purchaseaser.r. Supplier is required to obtain necessary information from Purchaser or other reliable Supplier is required to obtain necessary information from Purchaser or other reliable sources.
sources. Any and Any and all claims arising from lacall claims arising from lack of k of knowledge of required knowledge of required information willinformation will be rejected by Purchaser.
be rejected by Purchaser. 1.3
1.3.3.3 ExcExcepteptionions or variats or variationions shown in the Pros shown in the Projecject Specit Specificaficationtions take precs take precedeedence ovence overr requirements shown herein. No variations from the Project Specification and this design requirements shown herein. No variations from the Project Specification and this design standard are permitted unless approved in writing.
standard are permitted unless approved in writing. 2
2..00 RREEFFEERREENNCCEESS
Codes and Standards Codes and Standards
The following documents, including applicable addenda, constitute a part of this specification as The following documents, including applicable addenda, constitute a part of this specification as described herein.
described herein. The referenced edition of these documents shall be The referenced edition of these documents shall be that which is in effect as of thethat which is in effect as of the issue date of this specification
issue date of this specification.. API
API American Petroleum InstitAmerican Petroleum Instit uteute Pu
Publ bl 22221818 FiFirereprproooofifing ng PrPracactiticeces is in Pn Petetroroleleum um anand Pd Petetrorochchememicical al PrPrococesessisingng Plants-Second Edition
Plants-Second Edition ACI
S
Sttdd. 3. 31188 BBuuiillddiinng Cg Coodde Re Reeqquuiirreemmeennt ft foor Rr Reeiinnffoorrcceed Cd Coonnccrreettee S
Sttdd. . 550066 GGuuiidde e tto o SShhoottccrreettee ASTM
ASTM American Society of Testing and MaterAmerican Society of Testing and Mater ialsials C
C3333 SSppeecciiffiiccaattiioon n ffoor r CCoonnccrreette e AAggggrreeggaatteess C
C115500 SSppeecciiffiiccaattiioon n ffoor r PPoorrttllaannd d CCeemmeenntt D
D669955 TTeesst t MMeetthhood d ffoor r CCoommpprreessssiivve e PPrrooppeerrttiiees s oof f RRiiggiid d PPllaassttiiccss D
D779900 TTeesst t MMeetthhood d ffoor r FFlleexxuurraal l PPrrooppeerrttiiees s oof f UUnnrreeiinnffoorrcceed d PPllaassttiiccs s & & EElleeccttrriiccaall Insulation
Insulation D
D22224400 TTeesst Mt Meetthhood d ffoor Rr Ruubbbbeer Pr Prrooppeerrttiiees s – – DDuurroommeetteer Hr Haarrddnneessss D
D44554411 TTeesst t MMeetthhood d ffoor Pr Puullll--OOfff Sf Sttrreennggtth h oof f CCooaattiinnggs s UUssiinng g PPoorrttaabblle e TTeesstteerrss E
E8844 TTeesst t ffoor r SSuurrffaacce e BBuurrnniinng g CChhaarraacctteerriissttiiccs s oof f BBuuiillddiinng g MMaatteerriiaallss U
ULL UUnnddeerrwwrriitteerrs s LLaabboorraattoorriieess U
UL 1L 1770099 UUL SL Sttaannddaard rd fofor Sr Saaffeety ty RRaappid id RRisise Fe Fiire re TTeessts ts oof Pf Prorotteecctitioon Mn Maatteeririaalls fs foorr Structural Steel-Third Edition, Reprint with Revisions Through and Structural Steel-Third Edition, Reprint with Revisions Through and Including April 6, 2007
Including April 6, 2007 S
SSSPPCC SStteeeel l SSttrruuccttuurrees s PPaaiinnttiinng g CCoouunncciill AB-1
AB-1 Abrasive Grade 1 or 2Abrasive Grade 1 or 2 P
PAA--22 MMeeaassuurreemmeennt t oof f DDrry y PPaaiinnt t TThhiicckknneesss s wwiitth h MMaaggnneettiic c GGaaggeess S
SPP--11 SSoollvveennt t CClleeaanniinngg S
SPP--66 CCoommmmeerrcciiaal l BBllaasst t CClleeaanniinngg S
SPP--77 SSwweeeep p BBllaasst t CClleeaanniinngg S
SPP--1100 NNeeaarr--WWhhiitte e BBllaasst t CClleeaanniinngg 2.
2.11 InInteternrnatatioionanal Pl Prorotetectctivive Coe Coatatining / Ag / Akzkzo No Nobobelel C
C1177009 9 AAPPP P MMAAN N UUKK, , RReevv..00 AApppplliiccaattiioon n MMaannuuaal l ffoor r CChhaarrtteek k 11770099 Fire
Fire ProtProtectectionion QC QC MAN MAN GB, GB, RevRev. . 44 Quality Quality ConControl trol ManManual ual for for ChaChartek rtek FireFireprooproofingfing Systems Application
Systems Application 2
2..22 PPPPGG Pi
Pitttt-C-Chahar XPr XP PrProjojecect Apt Applplicicatatioion Man Manunualal 3
3..00 DDEEFFIINNIITTIIOONNSS 3.
3.11 HHazazaardrdouous s EEququiipmpmenent t anand d PPiipipingng
Hazardous equipment and piping is defined (for fireproofing) as that which contains material that Hazardous equipment and piping is defined (for fireproofing) as that which contains material that is flammable, toxic or dangerous to personnel.
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
Equipment such as vessels, exchangers, tanks, drums, fin fan coolers and piping which contain hydrocarbon is considered hazardous.
Internal combustion engines, pumps, and compressors are considered nonhazardous. 3.2 Hazardous Area
A hazardous area is defined as any area within 30 ft (9.2 m) horizontally and 30 ft (9.2 m) vertically of a potential source of fire. Fire hazardous area for each unit is defined in the Project Fire Hazardous Area Drawings.
3.3 Fire Protection (Fire rating)
The hours of protection are defined as the number of hours of exposure to rapid rise fire (UL 1709) while maintaining steel temperature below 1000° F (538° C) unless otherwise specified. 4.0 REQUIREMENTS
4.1 Extent of Fireproofing 4.1.1 Structural Steel
When supporting fire potential equipment within the battery limits, columns
and the beams transmitting the equipment load to the columns shall be fireproofed from their bases to the height of fire potential equipment or 30 feet (9.2 meters) above grade, whichever is greater. Fireproofing in this area shall have a 2-hour, UL 1709 (typical), rating.
All bracing carrying vertical loads shall be fireproofed when it is part of a
fireproofed supporting system. Bracing used only for wind loading shall not be fireproofed.
Platforms, runways, stairways, and their supports shall not be fireproofed The top flange of structural steel beams that support fire potential equipment
shall not be fireproofed. 4.1.2 Pipe Racks
Both the vertical and transverse horizontal members of the first level of pipe
racks located within 30 feet (9.2 meters) of fire potential equipment shall be fireproofed. Fireproofing in this area shall have a 2-hour rating. Pipe rack structures more than 30 feet (9.2 meters) from any fire potential equipment normally would not need fireproofing unless unusual conditions of exposure or loading exist. Beams parallel to the pipe shall not be fireproofed.
If air cooled exchangers are installed above pipe racks, the upper transverse
levels of the pipe racks shall be fireproofed including the full height of the vertical columns. All horizontal structural members supporting air cooled exchangers, including those cantilevered beyond the vertical supports, shall be fireproofed.
Knee braces and tee supports bearing heavy or critical piping shall be
fireproofed.
The top flange of pipe bearing beams shall not be fireproofed
4.1.3 Equipment Supports
All lugs, brackets, skirts, and legs supporting fire potential equipment located
within the fire potential area shall be fireproofed.
Saddles supporting equipment and measuring more than 1 foot (310 mm) in
height at their lowest points shall be fireproofed within the fire potential area.
Fireproofing in this area shall have a 2-hour rating.
4.1.4 Skirts Supporting Fire Potential Equipment
The outside of skirts supporting process vessels shall be fireproofed. The inside of skirts over 4 feet (1.2 meters) in diameter.
Skirts 4 feet (1.2 meters) and less in diameter shall not be fireproofed on the
inside.
Skirts which require insulation shall be fireproofed on the uninsulated
portions only. 4.1.5 Heaters
Structural members supporting fired heaters above grade should be
fireproofed for heaters handling flammable or combustible liquids. Structural steel members supporting fired heaters in other services should be fireproofed if located within a fire-scenario area. These include fired heaters in other-than hydrocarbon service, such as steam superheaters or catalytic cracking-unit air heaters, if a collapse would result in damage to adjacent hydrocarbon-processing equipment or piping.
If structural support is provided by horizontal steel beams beneath the
firebox of an elevated heater, fireproofing should be considered for the beams, unless at least one flange face is in continuous contact with the elevated firebox.
4.1.6 Reboilers
Supporting lugs and steel supporting reboilers shall be fireproofed. All beams and columns supporting reboilers shall be fireproofed regardless of the elevation of the reboilers.
4.1.7 Electric Power and Instrument Cable
Electric, instrument, and control systems used to activate equipment needed to control a fire or mitigate its consequences (such as emergency shutdown systems and isolation valves) should be protected from fire damage, unless they are designed to fail-safe during a fire exposure. If the control wiring used to activate emergency shutdown devices (including depressurization or isolation system) during a fire could be exposed to the fire, the wiring should be protected against a 15 minute fire-exposure functionally
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
equivalent to the conditions of UL 1709. If activation of these emergency systems would not be necessary during any fire to which it might be exposed, then protection of the wire is not required for emergency response purposes.
The primary methods of avoiding early cable failure in a fire situation that could prevent the safe shutdown of a plant include the following:
a. Locate isolation and emergency valves outside fire potential area b. Burying cable below grade
c. Routing cable around areas that have a high fire potential d. The use of fireproofed cable trays/conduits
e. The use of L.V. “Fire Resisting” cables 4.1.8 Pneumatic and Hydraulic Instrument Lines
Pneumatic and hydraulic instrument lines shall be protected for the same reason as described in 4.1.7. If Pneumatic and hydraulic instrument lines are from the stainless steel tubing which is highly resistant to failure during a hydrocarbon fire and do not have to be fireproofed with insulating material.
4.1.9 Control Valves
The control valves and their activators that should operate during a fire should be protected by various insulating systems that use preformed fire resistant material such as:
a. K-Mass
b. Lace-up fire resistance blankets
c. Insulation with stainless steel jacketing
The control valves should be protected against a 15 minute fire-exposure functionally equivalent to the conditions of UL 1709.
5.0 PAINTING
5.1 Prior to fireproofing, all surfaces shall be coated per the coating specification. Concrete fireproofing shall be applied directly over galvanized steel. For intumescent fireproofing material, manufacturer’s recommendation and requirements in Appendix A or Appendix B shall be followed.
5.2 All studs or clips welded to the steel surface shall be spot cleaned and touch-up primed. 5.3 Prior to fireproofing, all surfaces shall be free of dirt, grease and coating holidays.
6.0 MATERIAL
6.1 Concrete or Lightweight Concrete: Form Placed Method and Pneumatically Applied
6.1.1 Concrete for both manual and pneumatic placement shall be mixed in the proportion as determined by the applicator in accordance with Supplier’s recommendation so as to obtain a minimum compressive strength of 2000 psi at 28 days. Water/cement ratio shall
not exceed 0.50. Ready-mixed concrete in accordance with ASTM Specification C94 may be used.
6.1.2 Thickness for concrete or lightweight concrete shall be 2 inches (50 mm) minimum. 6.1.3 Portland cement shall be in accordance with ASTM Specification C150.
6.1.4 Aggregate
Form Placed Method
Fine and coarse aggregate shall conform to ASTM Specification C33 for concrete and C330 for lightweight concrete. Maximum aggregate size shall be limited to ½ in (13 mm).
Pneumatically Applied
Fine aggregate (sand) shall conform to ASTM Specification C33 for concrete and C330 for lightweight concrete. Maximum aggregate size shall be limited to ¼ in (6.4 mm).
Water shall be cold, clean and free of oils, acids, salts or other substances
injurious to the concrete. Water of drinkable quality is acceptable 6.2 Lightweight Cementitious Products
6.2.1 Commercial lightweight cementitious products are acceptable only when in compliance with the following quality criteria. Ablative coatings, gypsum, and magnesium oxychlorides are not acceptable.
6.2.2 Product must be listed by the Underwriters Laboratories, Inc., for exterior use based upon testing in accordance with UL 1709.
6.2.3 Fireproofing material shall contain no asbestos, toxic, or “red label” solvents.
6.2.4 Fireproofing Supplier shall furnish a list of current installations utilizing the product in question. This list shall contain the locations, type and years of service.
6.2.5 Lightweight products should not be used where structures are susceptible to mechanical abuse (grade to 8 feet (2.44 meters) – use concrete only).
6.2.6 Lightweight cementitious material shall be Pyrocrete 241 as manufactured by Carboline or approved equal.
6.2.7 Thickness for lightweight cementitious material shall the manufacturer’s recommendation.
6.3 Intumescent Mastic (See Appendix A and B for Material Requirements)
6.3.1 Intumescent mastic material shall consist of a fibrated mastic material in ready mixed form nonflammable when cured, durable under extreme weather conditions and suitable for temperature to 250° F (121 °C). It is a proprietary material.
6.3.2 Thickness for intumescent mastic fireproofing shall be per manufacturer’s recommendation.
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
6.3.3 Intumescent mastic material shall be from the following manufacturer or approved equal.
Chartek 1709 - manufactured by International Paint Ltd. Pitt-Char XP - manufactured by PPG
6.4 Reinforcement
6.4.1 Concrete or Lightweight Concrete Fireproofing
Welded wire mesh shall be 2 in x 2 in (50 mm x 50 mm), 12/12 gauge.
Annealed stainless steel wire shall be used for tie wire mesh where
necessary.
6.4.2 Lightweight Cementitious Fireproofing
Metal lath shall be 3.4 lb/yd2 (1.84 kg/mg2) galvanized diamond metal lath.
6.4.3 Intumescent Mastic Fireproofing
Reinforcement for Chartek 1709 – HK-1 (M) (hybrid carbon and glass
composite mesh).
Reinforcement for Pitt-Char XP – Galvanized Steel Hardware Cloth ½” x ½”
x 19 gage 6.5 Waterproof Mastic
6.5.1 Waterproof Mastic shall be Pecora Silicone No. 864 or approved equal. 6.5.2 Primer shall be P-65 or approved equal.
7.0 INSTALLATION
7.1 Concrete Fireproofing
7.1.1 Concrete fireproofing shall be used for equipment supports (skirts, saddles, and legs). Over light weight concrete, 8 ft of steel column from grade level, shall have two inch (50 mm) minimum thickness pneumatically applied or poured in place concrete.
The concrete shall be held in place by wire mesh as defined below.
Fireproofing need not be rubbed to a smooth finish, provided there is no
honeycombing.
Fireproofing shall have the equivalent of a wood float finish. Any cracks wider than 1/16 in. (1.5 mm) shall be repair ed.
7.1.2 Wire mesh shall be secured to studs or clips welded to the steel structure approximately 18 in. (450 mm) apart and shall be fastened approximately ¾ in. (19 mm) from the surface of the steel work. Clips and studs shall not be longer than 1 in. (25 mm).
Seller shall add crimp rods on beams and columns as required to support
reinforcement for fireproofing materials.
7.1.3 Any unusual details such as reboiler supports necessary for applying fireproofing to structural steel members shall be shown on the structural steel drawings.
7.1.4 All exposed concrete corners shall be chamfered or rounded.
Top surfaces shall be sloped for drainage. Exposed joints between steel and concrete shall be sealed with waterproof mastic equal to Pecora Silicone No. 864 with the Pecora P-65 primer.
7.1.5 All joints between fireproofing and steel shall be chipped or tooled and filled with a sealing compound, Thiokol base sealant, Pecora sealant or authorized equal to prevent the intrusion of moisture.
7.2 Lightweight Cementitious Fireproofing
7.2.1 Fireproofing of structural steel shall be with either concrete or lightweight cementitious material. Thickness of the concrete shall be 2 in. (50 mm) minimum. Thickness of the special material shall be per manufacturer’s recommendation.
7.2.2 When fireproofing is required for structural elements, all sides of the steel shape shall be covered except the top flange of beams which support process equipment, flooring, piping, etc.
7.2.3 Concrete fireproofing on all sides of beams and columns shall be applied in accordance with Paragraph 7.1 of this specification.
7.2.4 Lightweight fireproofing material shall be held in place by 3.4 lb/yd2 galvanized diamond metal lath.
7.2.5 A final surface resembling a wood float finish shall be considered satisfactory.
7.2.6 For columns and beams of contour design, naturally rounded off corners of proper thickness are acceptable.
7.2.7 On columns and beams boxed design construction shall not be used.
7.2.8 Caulking and sealing shall be done with product listed in Section 7.1.4 and 7.1.5. 7.3 Intumescent Mastic Fireproofing (See Appendix A and B for Application Requirements)
7.3.1 Intumescent Mastic fireproofing shall be used only where required and shall be identified by the Owner.
7.3.2 Intumescent Mastic fireproofing shall be installed as per manufacturer’s recommendation by certified applicator only.
7.3.3 Manufacturer’s representative should be present at beginning of application and follow up.
7.3.4 Surface preparation and primer coat shall be per manufacturer’s recommendation. 7.3.5 Top coat shall be applied as per manufacturer’s recommendation.
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
8.0 WORKMANSHIP 8.1 Preparation
8.1.1 Overspraying on adjacent piping, equipment, instruments, aluminium metal surfaces, etc. Is not acceptable. Seller shall protect all adjacent areas either by shielding by masking or covering with plastic tarps. Seller shall be responsible for removing all overspray fireproofing materials.
8.1.2 Fireproofing shall not be installed when temperature is below 40°F (5°C) or expected to be below 40°F (5°C) in next 24 hours. Seller shall provide suitable means of heating the newly installed fireproofing to a minimum of 40°F (5°C) for at least 24 hours after placing. Substrate temperatures shall always be above 40°F (5°C) when fireproofing is being applied.
8.1.3 Fireproofing shall not be installed during periods of high winds or rain. 8.1.4 Spot prime areas to be fireproofed where the shop preparation is damaged.
8.1.5 Steel members to receive fireproofing shall be cleaned, dried and made free of oil, dirt, and other foreign material.
8.2 Curing
8.2.1 Fireproofing material shall be cured per Manufacturer’s recommendation and shall be wetted as required to allow full curing.
8.2.2 Polyethylene film or wet burlap shall be used to retain moisture in curing of fireproofing material.
ATTACHMENT I
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
ATTACHMENT II
ATTACHMENT III
FIREPROOFING DETAILS USING CONCRETE MATERIAL
4. WELDED WIRE MESH SHALL BE USED IN LIEU OF HEXAGONAL POULTRY MESH AS STATED IN NOTE 3 ABOVE.
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
ATTACHMENT IV
ATTACHMENT V
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
APPENDIX A – APPLICATION OF INTUMESCENT FIREPROOFING USING CHARTEK 1709 1.0 Scope
This appendix covers requirements for material and application of intumescent fireproofing.
1.1 Blockout areas for field connection including bolt holes shall not be fireproofed in the shop but shall receive surface preparation and primer coat per this specification.
1.2 Blockout areas shall be kept to minimum. See structural steel drawings for the blockout details. 1.3 Installation details are shown in ATTACHMENT E
1.4 Top face of flange and top edges on beams supporting pipe and equipment shall not be fireproofed. The entire beam shall be blast cleaned per Section 7.2 and primed with Intergard 251 per Section 8.3. Top face including the edges shall be masked off during fireproofing application. All surfaces except top face and top edges shall be fireproofed with Chartek 1709 per this specification. The top face and edges (Non-fireproofed surface) shall receive one coat of Interzone 954, 10 mils (250 mcrons) MDFT and top coat of Interthane 990, 2 to 3 mils (50 to 75 microns) MDFT, Interzone 954 and Interthane 990 shall be applied after Chartek application. 1.5 All horizontal finished surface of fireproofing such as column base plate, top face of bottom
flange on beams, etc. shall have 50slope to prevent water ponding.
1.6 Fireproofing zone of galvanized columns shall be sweep blasted per Section 7.3 and primed with Intergard 251 primer per Section 8.3 prior to application of Chartek 1709.
1.7 Galvanized bolt on bolted connection shall be solvent wiped and surface shall be abraded with 80 grit sand paper, dust removed prior to application of Intergard 251 primerand finish off with Chartek 1709 and Interthane 990. This application can be combined with fireproofing of field block outs.
2.0 Applicator’s Responsibility
Applicator QA/QC responsibiliti es as follows
a. Supply the equipment for the specified inspections and tests required for fireproofing activities.
b. Supply new and undamaged fireproofing materials received at the shop or field jobsite in the manufacturer’s original sealed containers.
c. Proper storage of all materials in the area protected from weather before and during application d. Inspection of fireproofing materials and accessories prior to commencement of work. Any material
that has been damaged or found to be defective shall be removed and replaced by the seller at his expense.
e. Inspection during key construction phase include, proper storage of materials, surface preparation, primer application, equipment setup and application (Chartek 1709), Installation of reinforcing mesh (HK-1 M), Chartek 1709 thickness measurements and topcoat application
f. Applicator / Steel fabricator shall ensure that the applicator conforms to QC MAN GB, Rev.4. This includes (Samples attached to this specification )
Chartek Fireproofing - Area Quality Control Report Chartek Fireproofing Daily Log
Chartek Fireproofing Equipment Quality Control Report 3.0 Manufacturer Responsibility
A technical service audit shall be conducted by the manufacturer during the initial start of fireproofing and provide technical assistance during production phase.
4.0 Submittals
a. Applicator shall submit to the buyer a list of materials to be used in fireproofing and shall identify the specific design mix including manufacturer’s datasheets and MSDS sheets.
b. Applicator shall submit written procedures for storage, handling, surface preparation, environmental control, application, verification of fireproofing thickness, repair, and inspection of the fireproofing. Procedures shall be submitted to Purchaser for review and approval prior to using them.
c. Subcontractor shall submit to Purchaser for review fireproofing verification forms as specified in clause 2..0 (f). Daily inspection forms shall be accessible for spot review on a daily basis.
d. Fireproofing verification forms shall be used to verify that proper materials were used, and that accepted application procedures and specifications were followed. Fireproofing verification forms shall include a statement of completion conformance.
5.0 Materials 1. General
Fireproofing materials shall conform to C1709 APP MAN UK, Rev. 0 5.2 Primer
a. Primer shall be International Intergard 251
b. Mid coat for top face of flange on beam Interzone 954 c. Primer shall be approved and UL 1709 tested.
5.3 Chartek 1709
1. Fireproofing shall be CHARTEK 1709 manufactured by International Protective Coating/Akzo Nobel.
2. CHARTEK 1709 shall meet the requirements of UL1709, per XR design rating.
3. Fire rating of CHARTEK 1709 shall be 2 hour per UL1709 in accordance with CHARTEK 1709 Design XR625
4. CHARTEK 1709 shall have the following minimum physical properties: a. Dry density –62 lb/ft3
b. Compressive strength – 1,500 psi (determined in accordance with ASTM D695)
c. Hardness – Shore D 55-65 (determined in accordance with ASTM D2240) d. Flexural strength – 36,250 psi (determined in accordance with ASTM D790) e. Flame spread – Class A 25 (determined in accordance with ASTM E84)
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
f. Smoke developed – Class A 300 (determined in accordance with ASTM E84)
g. Adhesion strength to steel – 1450 psi (determined in accordance with ASTM D4541)
5. Testing shall be performed to determine physical properties for above items a, b, c, d, and g.
5.4 Reinforcing Mesh
1. Reinforcing mesh shall be HK-1 (M) (hybrid carbon and glass composite mesh). 2. Reinforcing mesh shall be supplied by the mastic manufacturer.
5.5 Topcoat
1. Topcoat shall be international Interthane 990 or as specified by the mastic manufacturer. . 2. Finish color shall be Medium Gray per RAL 7004.
6.0 Preconstruction Activities
6.1 Preconstruction Meeting
1. Project Engineer shall arrange for a preconstruction meeting with the following individuals in attendance:
a. Purchaser Project Engineer (primary project contact) b. Purchaser Non Metallic Technologist
c. Purchaser Lead Civil Engineer d. Purchaser QA/QC Inspector
e. Subcontractor representatives, including QC coordinator and foreman assigned to the job
f. Contractor structural steel fabrication/erection representative g. Manufacturer representative
2. Agenda to be covered at the preconstruction meeting shall include the followi ng: a. Review of Contractor’s submittals and this specification
b. Inspection hold points
c. Controls of environmental conditions in the shop d. Condition of steel necessary to accept fireproofing e. Surface preparation and compatible primer application
f. Fireproofing application, installation of reinforcement, and thickness measurements g. Cure measurement prior to application of topcoat
i. Exposure to elements only after system is completely sealed 6.2 Sample Preparation and Adhesion Testing
1. Applicator shall prepare a fireproofing sample on a 6 ft. long W10x49 carbon steel beam. The sample shall have pockets and tabs to represent complex shape.
2. Sample requires inspection and approval in writing by the Purchaser before the Applicator proceeds with application of the fireproofing.
3. Sample shall illustrate correct fireproofing appearance, thickness, reinforcing, and surface finish, and shall be used as the application standard.
4. Sample shall be tested for adhesion in accordance with ASTM D4541. a. Adhesion of primer to steel or galvanizing shall be a minimum of 300 psi. b. Adhesion of fireproofing to primer shall be a minimum of 300 psi.
c. Adhesion of topcoat to fireproofing shall be a minimum of 300 psi.
5. Owner or his representative, Contractor, Subcontractor, and Manufacturer shall approve the sample.
6. Two random production pieces that are shop fireproofed shall also be tested for adhesion. 6.3 Area Inspection
Area that will receive fireproofing shall be inspected to verify that ducts, piping, equipment, or other items that would interfere with application of fireproofing are not positioned until fireproofing work is complete.
7. Substrate Inspection and Preparation 7.1 Inspection
1. Substrate shall be inspected to verify that it is ready to be cleaned/blasted.
2. Substrate shall be uniform and free of defects, such as weld deficiencies, lack of seal welding, and poor drainage of galvanizing.
3. Any substrate defects that may adversely affect adhesion or performance of the fireproofing shall be properly repaired.
7.2 Non-Galvanized Substrate
1. Non-galvanized substrate shall be blasted in accordance with SSPC SP-10. 2. Blasted substrate shall have an anchor pattern of 2.0 to 3.0 mils minimum.
3. Specific abrasive shall be determined by the Applicator and approved by the Manufacturer prior to use.
7.3 Galvanized Substrate
1. Galvanized substrate shall be cleaned and degreased in accordance with SSPC SP-1. Alkaline cleaners shall not be used.
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
2. Cleaned substrate shall be blasted in accordance with SSPC SP-7/NACE No. 4. Abrasive shall conform to SSPC AB-1.
3. Blasted substrate shall have an anchor pattern that is sharp with no evidence of a polished surface.
8. Fireproofing Application
8.1 Ambient Considerations
1. Fireproofing shall be applied when:
a. Substrate temperature and ambient temperature are on the rise and greater than 50°F. b. Ambient temperature is 5°F above the dew point.
c. Relative humidity is less than 85%.
2. Areas where fireproofing is applied shall be ventilated for 24 hours after application. 3. Work area shall be kept clean and well ventilated.
4. Spillage and over-spray shall be removed promptly before material has cured. 8.2 Protection of Adjacent Areas
1. Adjacent equipment and surfaces that will not be fireproofed shall be protected from damage by over-spray, fall-out, or dusting.
2. Ducts in areas where fireproofing is being applied shall be closed and sealed. 8.3 Primer Application
1. Primer shall be applied to a dry film thickness (DFT) of 2 to 3 mils. Maximum allowable DFT on overlaps shall be 3 mils.
2. For non-galvanized substrate, primer shall completely cover the blast profile.
3. Prior to application of primer, on galvanized substrate, excessive zinc thickness may be reduced by sanding with P80-P-100 grade aluminum oxide abrasive paper for small areas. Polishing shall be avoided. For large surfaces, galvanized surface shall be sweep blasted per SSPC-SP7
8.4 CHARTEK 1709 Mixing
1. Properly mixed CHARTEK 1709 is light gray (with no striping).
2. A quality control check for mixing shall be a ratio check, performed by the Subcontractor. The ratio check shall be by weight as follows:
a. Weigh clean empty Parts A and B containers and note the respective weight.
b. Place the container under the ratio check valves located on the mixing block and open the valve at exactly the same time.
c. Close the valves when the containers are at least half full at exactly the same time. d. Calculate the ratio of Part A and Part B as a percentage of the total weight. Example
3. A minimum of two ratio checks shall be performed per shift, (1) start of the shift and (2) when the pump is shut down and restarted.
8.5 CHARTEK 1709 Application
1. Primer shall be allowed to cure for a minimum of twelve hours at 77°F before the CHARTEK 1709 is applied.
2. Before CHARTEK 1709 is applied, primed substrate shall be cleaned of dirt, dust, grease, oil, loose material, or other matter that may adversely affect CHARTEK 1709 bond.
3. CHARTEK 1709 shall be applied in accordance with APP MAN C1709, Rev 0.
4. CHARTEK 1709 materials shall be kept within a temperature range of 86˚F to 93˚ F for 24 hours prior to use.
5. CHARTEK 1709 shall be applied using plural component spray equipment. Equipment suppliers recommended by the Manufacturer are as follows:
a. Spray-Quip, Inc., 1754 Des Jardines, Houston, TX 77023 – Herb Chilman, Sr., 800-500-9109
b. Airtech Spray Systems, Inc., 4303 Pinemont, Houston, TX 77018 – Joe Acosta, 713-681-0013
6. Operating parameters for plural component spray equipment shall be in accordance with APP MAN C1709, Rev 1.
7. CHARTEK 1709 shall be applied to a minimum thickness of 10.7 mm per BYBU. XR 625 for 2 hour rating (UL 1709 certification directory).
a. Minimum thickness at any one point shall not be less than 85% of specified thickness. b. Overall average thickness shall be equal to, or greater than, the UL specified thickness. c. UL certified thickness is based on the average thickness.
8.6 Reinforcing Mesh Application
1. Reinforcing mesh shall be cut to required size before CHARTEK 1709 is applied.
2. Mesh shall be rolled thoroughly into the wet CHARTEK with short nap roller lightly dampened with International PMA solution.
3. Adjacent pieces of mesh shall be overlapped by a minimum of 2 in.
4. Mesh shall be placed at approximately mid thickness of the CHARTEK 1709. 5. Mesh shall be applied over flanges as shown on the details.
6. Mesh also shall be installed over web if web span is greater than 10 inches or as required per manufacturer’s application procedure.
8.7 Topcoat Application
1. Topcoat of Interthane 990 shall be applied in accordance with APP MAN C1709, Rev 0. 2. Unless otherwise specified, topcoat shall be applied within seven days after the CHARTEK
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sweep blasted or mechanically abraded with 40 grit paper (or equivalent) and solvent cleaned prior to applying the topcoat.
3. Topcoat shall be applied to a minimum DFT of 2 to 3 mils. 9. Inspection, Testing, and Repair
9.1 Daily Production Samples and Tests
1. Daily production samples shall be taken one per shift. Additional samples shall be taken if material batch numbers change. This can be accomplished by spraying material into a plastic cup and identifying sample number and date.
a. Samples shall be tested randomly to determine fireproofing hardness and density properties.
b. Sample shall be documented on the CHARTEK Fireproofing Daily Log. 2. The following inspections and tests shall be performed on a daily basis.
a. Degreasing stage – surface contamination – Visual, white cloth check for oils or other harmful contaminates [SOVENT WIPE TEST]
b. Blast cleaning – Visual inspection to ensure sheen surfaces are dulled by sweep blasting steel [VISUAL]
c. Primer – Wet film thickness measurements primer [WET FILM GAGE]
d. Inspect spray equipment – Operating conditions of plural component equipment [MATERIAL RATIO WEIGHT CHECK]
e. Application of CHARTEK 1709 – Inspect wet film thickness with approved [WET FILM GAGE Internationals Thickness Gauge ], observe mesh installation
f. CHARTEK 1709 dry film thickness test [approved electronic meter Ecometer Model 456 or 355 with either F3 or F6 probe]
g. Inspect cure of CHARTEK 1709 – [DUROMETER SHORE D] h. Topcoat – Inspect application of topcoat [WET FILM THICKNESS]
i. Environmental test equipment – Sling pychrometer, surface thermometer 9.2 Deficiency Inspection and Repair
1. Deficiencies in the fireproofing shall be inspected, noted, and properly repaired. Deficiencies include, but are not limited to, the following:
a. Cracks of any length in CHARTEK 1709.
b. Disbondment of primer, CHARTEK 1709, or topcoat c. Exposed reinforcing mesh
d. Inadequate fireproofing thickness.
e. Excessive mills and subsequent coating runs, drips, spills, and curtains.
2. Repair of deficiencies shall conform to Section 10.0 of APP MAN C1709, Rev 0. If necessary, Manufacturer shall write repair procedures not covered in APP MAN C1709.
3. A written repair procedure shall be submitted to the Purchaser before repairs are performed. 9.3 Hardness Test
1. CHARTEK 1709 shall be given a Shore D Hardness test 48 hours after CHARTEK application and before application of the topcoat.
2. Shore D Hardness test shall be performed using a Durometer gauge. 3. CHARTEK 1709 shall have a minimum hardness of 40 Shore D. 4. Hardness readings shall be taken on areas that are relatively smooth. 5. Ten readings shall be taken per area, discarding the low and high reading. 9.4 Density Test
1. Random daily production samples (see 8.1) of CHARTEK 1709 shall be tested for density a minimum of once per week.
2. CHARTEK 1709 shall have a minimum density of 62 lbs./ft
3
. 9.5 Final Inspection
Final inspection of the installed fireproofing shall be performed jointly by the Applicator and the Purchaser.
9.6 Test Results
Test results shall be recorded on “CHARTEK Fireproofing –Area Quality Control Report” and the “Fireproofing Daily log”.
10. Curing
Fireproofed surfaces shall not be exposed to the exterior elements until the fireproofing is completely cured and the topcoat is properly sealed over the entire fireproofed surface.
11. Shipping and Handling
All fireproofed steel shall be handled using nylon slings or other approved lifting methods. Proper dunnage during transport, storage and jobsite erection shall be used to minimize damage to the fireproofing.
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
ATTACHMENT A – CHARTEK® FIREPROOFING – AREA QUALITY CONTROL REPORT
Project:
Owner:
Owner’s representative:
Applicator’s representative:
Area identification: see attached drawing
Report Nº: XXX – A
Date:
Prepared by:
NOTES
AREA COMPLETE
Applicator:
Signature:
Name:
Owner:
Signature:
Name:
OPERATION DATE Nº TEST ACTIVITY (see QCP nº XXX) SIGNATURE SITE MANAGER/QC COMMENTS
BLAST CLEANING-PRIMER-MASKING
Blast
cleaning-primer
Acceptance of
surfaces
Masking
Sample area
CHARTEK APPLICATION-MESHING
1
stCoat
Mesh installation
2
ndCoat
TOPCOAT
1
stCoat
2
ndCoat
ATTACHMENT B-CHARTEK® FIREPROOFING DAILY LOG
PERSONNEL
Site Manager:
Site QA/QC Manager: Sprayers-trowellers: Owner’s QC Inspector:
ENVIRONMENTAL CONDITIONS (to be recorded every hour) Time Ambient temp. Relative humidity Dew point Substrate temp. MESH INSTALLATION
Mesh installed (type and surface area in m2): Edge mesh (Charlok) installed (linear meters):
CHARTEK STORAGE TEMPERATURE Part A Part B CHARTEK APPLICATION
Ratio (% in weight)
A.M. Part A Part B P.M. Part A Part B SPRAY EQUIPMENT ID (type and serial number):
ID areas coated (if different from drawing)
Specified thickness (mm) Thickness applied to date Thickness applied today Surface area coated (m2 )
Chartek quantity used (no. of kits) Part A Part B Solvent used : Type Quantity (lt.) CHARTEK BATCH NUMBERS
Part A: Part B: NOTES
Signature Site Manager-Site QA/QC Manager:
Project: Owner:
Owner’s representative: Applicator’s representative: Area identification:see attached drawing
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ATTACHMENT C- CHARTEK® FIREPROOFING EQUIPMENT QUALITY CONTROL REPORT
PLURAL COMPONENT SYSTEM
Machine type
Hose length
Preloading Chartek temperature Part A:
Part B:
Tank temperatures
Part A:
Part B:
Tank pressures
Part A:
Part B:
In-line heater temperatures
Part A:
Part B:
Displacement pump pressures
(at cylinder exit)
Part A:
Part B:
Line heat
Gun exit temperature
Spray gun
Tip size (1/1000”):
Fan size (mm):
NOTES
Signature Site Manager-Site QA/QC Manager:
Project:
Owner:
Owner’s representative:
Applicator’s representative:
Area identification: see attached drawing
ATTACHMENT D – UL Certification of Chartek 1709
Fire Resistance Ratings - ANSI/UL 1709
See General Information for Fire Resistance Ratings -ANSI/UL 1709 Design No. XR625
October 09, 2006
Ratings - 1/2, 3/4, 1, 1-1/2, 2, 2-1/2, 3, 3-1/2 Hr. (See Item 3)
1 Steel Column — Min. size W10X49. The column surfaces shall be free of dirt, loose scale and oil then primed with epoxy based primers to an approximate dry film thickness of 2 mils.
2 Flange Edge Reinforcement — Carbon fiberglass mesh Type HK-1 applied over the flange tips at approximately mid-depth of the total thickness of mastic coating.
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
3. Mastic Coating — Two component spray materials applied in one or more coats as described in the application instructions to the thickness shown below. Thickness below includes 2 mils (50 micron) of primer.
Rating, Hr
Material Thickness, Microns With Mesh (Item 2)
Material Thickness, Microns
Without Mesh (Item 2)
1/2 - 2740 3/4 - 4550 1 - 5780 1-1/2 8240 -2 10700 -2-1/2 13160 -3 15620 -3-1/2 18080
-INTERNATIONAL PAINT LTD — Type Chartek 1709. Investigated for exterior use.
4. Top Coat — One of the following topcoats shall be used. Two component polyurethane topcoat Type Interthane 990 applied at a dry film thickness of 50 microns. Two component
polyurethane topcoat Type Interthane 990HS applied at a dry film thickness of 50 microns. Two component polysiloxane topcoat Type Interfine 878 applied at a dry film thickness of 50 microns. Two component polysiloxane topcoat Type Interfine 979 applied at a dry film thickness of 100 microns.
*Bearing the UL Classification Mark Last Updated on 2006-10-09
Copyright © 2007 Underwriters Laboratories Inc. ®
The appearance of a company's name or product in this database does not in itself assure that products so identified have been manufactured under UL's Follow-Up Service. Only those products bearing the UL Mark should be considered to be Listed and covered under UL's Follow-Up Service. Always look for the Mark on the product.
UL permits the reproduction of the material contained in the Online Certification Directory subject to the following conditions: 1. The Guide Information, Designs and/or Listings (files) must be presented in their entirety and in a non-misleading manner, without any manipulation of the data (or drawings). 2. The statement "Reprinted from the Online Certifications Directory with permission from Underwriters Laboratories Inc." must appear adjacent to the extracted material. In addition, the reprinted material must include a copyright notice in the following format: "Copyright © 2007 Underwriters Laboratories Inc.®"
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
ATTACHMENT E – Installation Details (Continue)
Note:
HK-1 (M) Mesh is required on web if web dimension is greater than 10 inches (250
mm) and as required per Chartek 1709 Application Manual.
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
APPENDIX B – APPLICATION OF INTUMESCENT FIREPROOFING USING PITT-CHAR XP 1.0 Scope
This appendix covers requirements for material and application of intumescent fireproofing.
1.1 Blockout areas for field connection including bolt holes shall not be fireproofed in the shop but shall receive surface preparation and primer coat per this specification.
1.2
Blockout areas shall be kept to minimum. See structural steel drawings for the blockout details. 1.3 Installation details are shown in ATTACHMENT E.1.4 Top face of flange and top edges on beams supporting pipe and equipment shall not be fireproofed. The entire beam shall be blast cleaned per Section 7.2 and primed with SigmaCover 280 per Section 8.3. Top face including the edges shall be masked off during fireproofing application. All surfaces except top face and top edges shall be fireproofed with Pitt-Char XP per this specification. The top face and edges (Non-fireproofed surface) shall receive one coat of Amerlock 400 GF, 8-12 mils (200-300 mcrons) MDFT and top coat of ei ther Sigmadur 550 (gray) or Amercoat 450H, 2 to 3 mils (50 to 75 microns) MDFT. These coatings shall be applied after Pitt-Char XP application.
1.5 All horizontal finished surface of fireproofing such as column base plate, top face of bottom flange on beams, etc. shall have 50slope to prevent water ponding.
1.6 Fireproofing zone of galvanized columns shall be sweep blasted per Section 7.3 and primed with SigmaCover 280 per Section 8.3 prior to application of Pitt-Char XP.
1.7 Galvanized bolt on bolted connection shall be solvent wiped and surface shall be abraded with 80 grit sand paper, dust removed prior to application of SigmaCover 280 primer and finish off with Pitt-Char XP and approved top coat system. This application can be combined with fireproofing of field block outs.
2.0 Applicator’s Responsibility
Applicator QA/QC responsibiliti es as follows
a. Supply the equipment for the specified inspections and tests required for fireproofing activities.
b. Supply new and undamaged fireproofing materials received at the shop or field jobsite in the manufacturer’s original sealed containers.
c. Proper storage of all materials in the area protected from weather before and during application d. Inspection of fireproofing materials and accessories prior to commencement of work. Any material
that has been damaged or found to be defective shall be removed and replaced by the seller at his expense.
e. Inspection during key construction phase include, proper storage of materials, surface preparation, primer application, equipment setup and application (Pitt-Char XP), Installation of reinforcing mesh (Galvanized Steel), Pitt-Char XP thickness measurements and topcoat application.
f. Applicator shall ensure that the applicator conforms to latest QC Manual. This included (sample attached to this specification)
Pitt-Char XP Reference Smple
Pitt-Char XP Plural Equipment Daily Report Pitt-Char XP Daily Log
3.0 Manufacturer Responsibility
A technical service audit shall be conducted by the manufacturer during the initial start of fireproofing and provide technical assistance during production phase.
4.0 Submittals
4.1 Applicator shall submit to the buyer a list of materials to be used in fireproofing and shall identify the specific design mix including manufacturer’s datasheets and MSDS sheets.
4.2 Applicator shall submit written procedures for storage, handling, surface preparation, environmental control, application, verification of fireproofing thickness, repair, and inspection of the fireproofing. Procedures shall be submitted to Purchaser for review and approval prior to using them.
4.3 Subcontractor shall submit to Purchaser for review fireproofing verification forms as specified in clause 2.0 (f). Daily inspection forms shall be accessible for spot review on a daily basis.
4.4 Fireproofing verification forms shall be used to verify that proper materials were used, and that accepted application procedures and specifications were followed. Fireproofing verification forms shall include a statement of completion conformance.
5.0 Materials
5.1 General
Fireproofing materials shall conform to PPG Industries Pitt-Char XP Application Manual. 5.2 Primer
a. Primer shall be PPG SigmaCover 280.
b. Mid coat for top face of flange on beam PPG Amerlock 400GF c. Primer shall be approved and UL 1709 tested.
5.3 Pitt-Char XP 5.2
5.3
5.3.1 Fireproofing shall be Pitt-Char XP manufactured by PPG Industries Inc. 5.3.2 Pitt-Char XP shall meet the requirements of UL1709, per XR 612.
5.3.3 Fire rating of Pitt-Char XP shall be 2 hour per UL1709 in accordance with Pitt-Char XP Design XR 612
5.3.4 Pitt-Char XP shall have the following minimum physical properties: a. Dry density – 68 lb/ft3