Purpose
This method statement for fireproofing works describes the construction and control actions to be done to meet the requirements for lightweight concrete fireproofing works on structures and equipment skirt/support.
Table of Contents
Scope
The general specifications for materials and workmanship for all structural and equipment skirt/support lightweight fireproofing works are covered in the method statement.
References
Fireproofing Standards
Test design for fireproofing for structural steel
Promat Fendolite MII fireproofing system data sheets
Promat (CAFCO) Application Specifications Guidelines
Equipment and Materials
Equipment
Sprayer for fireproofing materials
Generator
Electric Grinder
Tank for potable water
Pump for water jets (if required)
Machine for CD Stud Welding
Materials
SBR Fendolite MII Poly Based on the manufacturer’s guideline for Fendolite
Galvanized welded wire mesh 50mm x 50mm with 1.6mm wire diameter for equipment (vessel skirts)
Galvanized welded wire mesh 50mm x 50mm with a wire diameter of 1.2mm to 1.6mm is used for structural steel members (columns, beams, bracing, etc.)
1.2 mm diameter galvanized tie wires
Sealant Poly Bond SBR must be applied as a key layer as deemed suited to the state of the primed surface
CD weld pins, 12°17mm x 3mm dia (structural steel members)
Material Handling and Storage
Storage and handling of materials must follow the manufacturer’s instructions. Fendolite MII as approved based on the material data sheet submitted: Until it is time to use the material, it must be kept dry, covered, and off the ground.
The materials must be examined upon receipt and the batch numbers and shipping date must be recorded. One year from the date of manufacture, the material is still useful.
Before the release of the subsequent consignment, each consignment must be completely consumed.
Mesh and other materials:
Up until the point of manufacturing, the materials must be stored in shaded containers. Extreme caution must be used when handling to prevent injuries from sharp edges.
When handling materials, safety precautions such as wearing hand gloves, goggles, a helmet, and safety boots are required.
Promaseal or a similar term Promat A silicon sealant with a shelf life of 12 months from the date of manufacture is called Promaseal or its equivalent.
Top coat:
The top coat must be kept in a cool, dry location. The product has a 12-month shelf life after the date of manufacture.
Fireproofing Work Procedure
For Steel Buildings Surface cleaning:
Before applying fireproofing material, make sure the surface is clear of pollution, including oil, grease, moisture, and other substances.
The contractor is responsible for ensuring that the primary contractor follows the project specifications when preparing the surface before releasing it for fireproofing.
Marking points should be placed at the proper center, depending on the size of the substrate member, on the surface of structural steel members with a staggered or diamond pitch.
The corrosion system at the grinded region needs to be restored to the original specification before Poly Bond SBR is applied.
Rotate Cafco Helical pins 90 degrees and do one test per square meter. The maximum permitted failure rate is 10%.
Sealer & Key coat “Poly Bond SBR” application:
Check for the loose mill, scale, oil, grease, apparent dampness, dirt, or other pollution on the surface that will be coated.
Correctly stir the mixture.
Since it is cured by air drying, external curing is not required.
“G.I mesh” mesh reinforcement/retention
The placement of reinforcement mesh must place essentially in the middle of the thickness. i.e., between 11 and 17 mm from the substrate.
Mesh must be secured by twisting the cut ends together or using galvanized wire ties at 150 mm intervals, with at least 50 mm of overlap required at all connections. At no point should more than three mesh apertures intersect.
The profile approach protects steel portions larger than 203mm X 203mm.
The solid fill method protects steel sections up to and including 203 mm x 203 mm between flanges. In this situation, the web section may be filled with Fendolite MII before the mesh is installed in order to prevent any voids from forming during the application of Fendolite MII.
FENDOLITE MII fire retardant mixture:
Ensure that the pump and mixing equipment is clean and in working order.
In an appropriate mixer, combine Fendolite MII and potable water. Use 15 to 19 liters of water for 20 kilograms of the bag. Potable water must have a maximum temperature of 35°C.
Fill the mixer with the majority of the necessary mixing water.
Continually add the packaged stuff. Until the mixture is the right consistency, gradually add the mixing water.
Three minutes must be spent mixing to achieve the mix’s optimum qualities. Refrain from adding more water as stated above.
To maintain supply continuity, it should be noted that there should be enough material placed nearby the pump and mixing apparatus.
FENDOLITE MII fireproofing material application:
When the substrate and air temperatures are between 49 °C and 50 °C, Fendolite MII can be used.
Use a plastic tarp to cover the application area while it is being applied to prevent fireproofing ingredients from spreading to nearby equipment or the surrounding area.
Using a sprayer machine, apply Fendolite MII material to the surface that has been prepared. For a 2-hour fire rating, the coat’s thickness must be maintained at 34 mm + 3 mm.
The right amount of air must be injected at the nozzle to maintain the consistency of the material’s texture and its approximate wet density, which should be between 700 and 1300 kg/m3.
It is forbidden to keep the spray head still. When possible, the spray head should be held at a 90° angle to the work area in order to provide even coatings. Apply no less than 8mm of material in a single coat as a general guideline.
If the materials are put in multiple coats, the first coat should have a spray texture finish or be thoroughly scratched to guarantee that the subsequent coatings will adhere smoothly.
A needle penetration gauge with a ruled indicator can be used to easily assess coating thickness.
Before putting on further coats, the surface should be thoroughly wet with fresh water if it has grown extremely dry.
Once the necessary thickness has been applied and has had a chance to be slightly firm, the finished work should be done with a trowel.
24 hours are needed for setting in order to attain the maximum thickness. The applied surface must be shielded from rain and running water during this time.
Use a trowel to manually apply for small repairs.
Excessive labor to obtain a smoother finish may cause future surface cracking. As a result, the finishing will only be done to keep the surface level and not to overly smooth it for aesthetic reasons.
For skirts or support for equipment: Surface cleaning:
Before applying fireproofing material, make sure the surface is clear of pollution, including oil, grease, moisture, and other substances.
Verify that the main contractor performs surface preparation prior to release for fireproofing in accordance with project requirements.
A good metal-to-metal contact is necessary for a good weld, so wipe away any corrosion protection system or paint at the designated location using an electric or air-driven wire brush until a brilliant metal surface is obtained.
The corrosion system at the grinded region needs to be restored to the original specification before Poly Bond SBR is applied.
Sealer & Key coat “Poly Bond SBR” application:
Check for the loose mill, scale, oil, grease, apparent dampness, dirt, or other pollution on the surface that will be coated.
Correctly stir the mixture.
Since it is cured by air drying, external curing is not required.
“G.I mesh” mesh reinforcement/retention
The placement of reinforcement mesh must place essentially in the middle of the thickness. i.e., between 11 and 17 mm from the substrate.
Mesh must be secured by twisting the cut ends together or using galvanized wire ties at 150 mm intervals, with at least 50 mm of overlap required at all connections. At no point should more than three mesh apertures intersect.
Combining FENDOLITE MII, a fire-resistant material
Ensure that the pump and mixing equipment is clean and in working order.
In an appropriate mixer, combine Fendolite MII and potable water. Use 15 to 19 liters of water for 20 kilograms of the bag. Potable water must have a maximum temperature of 35 degrees C.
Fill the mixer with the majority of the necessary mixing water.
Gradually add the bagged material. Until the mixture is the right consistency, gradually add the mixing water.
Three minutes must be spent mixing to achieve the mix’s optimum qualities. Refrain from adding more water as stated above.
To maintain supply continuity, it should be noted that there should be enough material placed nearby the pump and mixing apparatus.
Application of FENDOLITE MII to Equipment and Saddle Support
When the substrate and air temperatures are between 49 °C and 50 °C, Fendolite MII can be applied.
Use a plastic tarp to cover the application area while it is being applied to prevent fireproofing ingredients from spreading to nearby equipment or the surrounding area.
Using a sprayer machine, apply Fendolite MII/material to the surface that has been prepared. For a 2-hour fire rating, the coat’s thickness must be maintained at 34 mm + 3 mm.
The right amount of air must be introduced at the nozzle to maintain the material’s consistency in texture and approximate wet density, which should be between 700 and 1300 kg/m3.
It is forbidden to keep the spray head still. When possible, the spray head should be held at a 90° angle to the work area in order to provide even coatings. Apply no less than 8mm of material in a single coat as a general guideline.
If the materials are put in multiple coats, the first coat should have a spray texture finish or be thoroughly scratched to guarantee that the subsequent coatings will adhere smoothly.
A needle penetration gauge with a ruled indicator can be used to easily assess coating thickness.
Before putting on further coats, the surface should be thoroughly wet with fresh water if it has grown extremely dry.
Once the necessary thickness has been applied and has had a chance to be slightly firm, finish work should be done with a trowel.
24 hours are needed for setting in order to attain the maximum thickness. The applied surface must be shielded from rain and running water during this time.
Use a trowel to manually apply for small repairs.
Excessive labor to obtain a smoother finish may cause future surface cracking. As a result, the finishing will only be done to keep the surface level and not to overly smooth it for aesthetic reasons.
For steel equipment skirts and supports
Surfaces protected by Fendolite MII should be sloped where there is a chance of water accumulating on them so that they can drain away. This is crucial for beams because it protects the top flange and the top surface of the bottom flange when it follows the profile of a beam.
Hot weather conditions for equipment skirts and supports and steel structures
In hot, dry conditions, it’s important to prevent the Fendolite MII coating’s moisture content from evaporating too quickly. Too much water evaporates too quickly, leaving insufficient water for cement to fully hydrate.
Covering the exposed members with wet hessian sacks that need to be periodically moistened or covering the exposed members with polyethylene sheeting to retain moisture. It is advised to use this protection during hot weather for at least three days.
Joints for equipment skirts and supports and steel structures
At all steel junctions, a “U”-shaped groove must be cut and filled with silicone or elastomeric sealant.
Applying the top coat to equipment skirts and supports and steel structures for fireproofing: Surface Cleaning
To achieve a sound, clean surface free of laitance, oil, grease, dust, or other contaminants, all concrete surfaces should be treated. The temperature of the substrate must be greater than 5°C and at least 3° above the dew point.
Application
Sigmacover 410 is a two-component, polyamide-cured epoxy coating with high solids content that can be applied by airless spray, brush, or roll.
The base-to-hardener mixing ratio is 80:20. Before use, thoroughly stir.
The ideal paint temperature is above 15°C; otherwise, additional thinner may be needed to achieve the desired application viscosity. Reduced sag resistance results from using too much solvent. Thinner (as per the manufacturer’s recommendations) shall be added after mixing the components.
Sigmacover 410 shall be applied as a top coat in two layers as per the manufacturer’s recommendations. The recommended dry film thickness shall be 75 to 150 microns.
Repair procedure for steel structures and equipment skirts/supports
Cut away any loose fireproofing material by chamfering any sharp edges. Where mesh reinforcement is exposed, clear the fireproofing material away from the mesh and ensure that it will remain in the mid-third of repair.
If damage has resulted in mesh failure, totally remove the affected mesh and reinstate it with new mesh ensuring that a minimum 50mm overlap onto the original mesh is achieved and that is secured by the use of wire ties or twisting cut ends together.
Remove loose dust.
If the existing fireproofing material has become very dry, dampen the surface adjacent to the repair site with potable water.
Mix and apply the fireproofing material and finish level with the existing material.
Inspection
The QA/QC Inspector shall inspect each activity to verify that it has been correctly applied, and record it in the Fireproofing Checklist prior to final inspection. Checks shall include but are not limited to:
Preparation of the surface.
Installation of attachments.
Reinforcement mesh installation.
The thickness of fireproofing materials, key coat.
Wet density and slump of Fireproofing material.
Temperature (ambient, water, and substrate) during application.
Application of fireproofing material.
Proper curing.
Batch number & expiry date.
Records for Method Statement for Fireproofing Works
Checklist for Fireproofing work
Material Data Sheet/Test Certificate
Material Safety Data Sheet
Surface Preparation
Density and temperature monitoring sheet form
Health and Safety
All work permits (as applicable) shall be obtained prior to commencing any work.
All the persons involved shall be briefed on the health hazard and shall be provided with the required PPE.
Attachments
Job Safety Analysis (JSA)
Typical Inspection Plan
Product Data Sheet
tags: method statement for fireproofing works