TSI TECHNICAL NOTE 90181

ENGINEERING DESIGN INFORMATION

THERMO-LAG 330-1 SUBLIMING COATING

ENVELOPE SYSTEM

FOR FIRE RESISTIVE ENHANCEMENT

OF CRITICAL COMPONENTS OF

NUCLEAR POWER GENERATING FACILITIES

Siif040244 8ii026PDR ADQCK 05000387F PDR VOLUME TWO

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THE ATTACHED FILES ARE OFFICIAL RECORDS OF THEDIVISION OF DOCUMENT CONTROL. THEY HAVE BEENCHARGED TO YOU FOR A LIMITED TIME PERIOD ANDMUST BE RETURNED TO THE RECORDS FACILITYBRANCH 016. PLEASE DO NOT SEND DOCUMENTSCHARGED OUT THROUGH THE MAIL. REMOVALOF ANYPAGE(S) FROM DOCUMENT FOR REPRODUCTION MUSTBE REFERRED TO FILE PERSONNEL.

AUGUST 1981 RECORDS FACILITYBRANCH

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INC.

3260 BRANNON AVE. ~ ST. LOUIS, MISSOURI 63138

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TABLE OF CONTENTS

VOLUME ISECTION TITLE

ABSTRACT

THERMO-LAG

GENERAL METHOD OF OPERATION

TSI TECHNICAL NOTE 71880

PART 1 — -THERMO-LAG 330 SUBLIMING COATINGLISTING OF SELECTED APPROVALS FROMINDEPENDENT TESTING AND UNDERWRITINGAGENCIES

PART 2 — REFERENCE LIST OF SELECTED USERSOF THERMO-LAG SUBLIMING COMPOUNDS

PHOTOGRAPHS OF THERMO-LAG 330-1 SUBLIMINGCOATING INSTALLATIONS

DATA SHEETS FOR:

THERMO-LAG 330-1 SUBLIMING COATINGTHERMO-LAG 350 TWO PART SPILL RESISTANCE TOPCOATTHERMO-LAG STRESS SKIN TYPE 330-69THERMO-LAG 330-70 CONFORMABLE CERAMIC BLANKETTHERMO-LAG FIBERGLASS ARMORING

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TABLE OF CONTENTS

(CONTINUED)

VOLUME I

SECTION TITLE

ENGINEERING REPORT ON ONE HOUR ASTM E119 FIRESIMULATION FACILITY FIRE TEST FOLLOWED BY A SHORTTERM WATER HOSE STREAM IMPACT TEST ON A NUCLEARFACILITY CLASS 1E CABLE TRAY, CONDUITS AND AIRDROP ASSEMBLY

FIRE ENDURANCE TESTS ON CABLE TRAYS, CONDUITSAND CABLE DROP ASSEMBLIES PROTECTED WITHTHERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM

ENGINEERING REPORT ON ONE HOUR ASTM E119 FIRESIMULATION FACILITY FIRE TEST FOLLOWED BY A SHORTTERM WATER HOSE STREAM IMPACT TEST ON A NUCLEARFACILITY CLASS 1E CABLE CONDUIT ASSEMBLY

UNDERWRITERS LABORATORIES REPORT NOS. R6076SURFACE BURNING CHARACTERISTICS OF GENERAL PURPOSECOATINGS

A. THERMO-LAG 330-1 SUBLIMING COATING

B. THERMO-LAG 350 TWO PART SPILL RESISTANT TOPCOAT

10 TSI TECHNICAL NOTE 10280EVALUATION OF THE WEATHERING CHARACTERISTICS OFTHERMO-LAG 330-1 SUBLIMING COMPOUND AS APPLIED TOMETAL SUBSTRATES

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TABLE OF CONTENTS

(CONTINUED)

VOLUME II

SECTION TITLE

THREE HOUR TESTS ON THERMO-LAG 330

UNDERWRITERS LABORATORIES DESIGN'NO. X611MONSANTO SPECIAL REPORT 8008FACTORY MUTUAL REPORT NUMBER 23187FACTORY MUTUAL REPORT NUMBER'23187.1

12 UNDERWRITERS LABORATORIES FILE NO. 6802-7REPORT ON THE PERFORMANCE OF A STEEL LOADBEARING WALL ASSEMBLY PROTECTED WITH A'MASTICCOATING DURING'FIRE AND HOSE STREAM TESTS

13 UNDERWRITERS LABORATORIES FILE NO. R6802FIVE HOUR FIRE TESTS PER ASTM E119

THREE HOUR FIRE ENDURANCE TESTS ON TSI'SCONFORMABLE THERMO-LAG 330 STRESS SKINFIRE WALL ASSEMBLY

15 FACTORY MUTUAL REPORT NO. 23160.1TWO HOURS FIRE ENDURANCE TEST

16 INTERIM MEMORADUM REPORT NO. 459COMPARISON OF VARIOUS THER'YSTEMS FOR THEPROTECTION OF RAIL TANK CARS TESTED AT THEFRA/BRL TORCHING FACILITY

TABLE OF CONTENTS

(CONTINUED)

VOLUME II

SECTION TITLE

TSI TECHNICAL NOTE 77629THERMO-LAG'30 SUBLIMING COATING SYSTEMSELECTED DATA ON WATER IMPINGEMENT,TESTS,FULL SCALE TORCH TESTS AND FIRE ENGULFMENTTESTS

18 PRELIMINARY ACCIDENT REPORTTANK CAR DERAILMENTJOAQUIN; TEXAS

19 TSI TECHNICAL NOTE 80181THERMO-LAG 330-1 SUBLIMING COATINGENVELOPE SYSTEM APPLICATION PROCEDURES

20 OUTLINE OF TSI'S QUALITY ASSURANCE ANDQUALITY CONTROL SYSTEM

UXDERM'RITERS LABORATORIES l.iC.st) rflk)nTE> >ntttl K>rrf>tsal%%, t lla~l I4%%

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R6S02

Yorttbrook, ILJanuary 9, 1979

TSI, Inc.3260 Brannon Ave.St; Louis, liO 63139

Atten tion: R. Fe 1 dman

Subject: MASTIC COATINGS (CDWZ)

Gentlemen:

We are enclosing one copy of the Report revision covering-the above subject. The revision consists of the folloving:

Revised illustration 6 for report issued 6-5-78,dated 1-S-79.

Very truly yours,

G. D. PalikijFire Protection Dept.

GP-.r gencl.

Guide BXUV.Ftro )tcalatanco Ratings.

Design No. X6llRotint)—3 Hr.

1978Novctnbcr 3,t)tS11-A card.)

(Continued on Xstl-8 card.)

This card is issued by Un rwritcrs Laboratories Inc. I>

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ILL.6R 6802-6A

an independent, nu.'-fur-prufi t organi "at''un testi nyJ'or puolic safety

File R6802-6AProject 77NK422

June 5 1978

REPORT

on

MASTIC COATING APPLIED TO AM14X228 STEEL COLUMN

YSI, Inc.St. Louis, Missouri

Copyright C 1978 Underwriters Laborator ies Inc.Underwriters Laboratories Inc. authorizes the above namedcompany to reproduce this Report provided it is reproduced inits entirety.

File R6802-6A Page G 1 Issued: 6-5-78

GENERAL

The subject of this Repor t is the fire resistanceClassification of a W14X228 steel column protected with Type 330mastic subliming coating applied to a dry film thickness'f15/32 in. as described in the section entitled "Protection of TestAssembly," and as shown in ILL. 1.

The object of this investigation was to establish a fireresistance Classification for the column described herein by meansof a fire endurance test conducted in accordance with the Standardfor Fire Tests of Building Construction Materials, UL263 (ASTME119, NFPA No. 251) .

In addition to the fire endurance test, the submittorr equested that we conduct an engineer ing evaluation of the testsde"cubi.bed in this Repor t and their column tests described inRepor ts R6802-3 and R6802-4, to determine the minimum dry filmthic'kness of the Type 330 mastic coating necessary to afford a

3 hr fire resistance rating when applied to a W14X228 steelcolumn. F

I

The fire test was supplemented'y other tests andexaminations to furnish information regarding the composition and

,.physical proper ties of the mater ials used and to determine thepracticability of handling and applying the coating.

GDP/RHB: plh

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File R6802-6A Page 1 Issued: 6-5-78

DESCRIPTION

EXAMINATION OF HATERIALS:

The materials used in the test assembly are described below..

Column — The column used in the test assembly was a W14X228steel section measuring 8 ft, 3 in. long between the top andbottom concrete caps.

Primer — The pr imer was a corrosion inhibiting modified alkydpr imer manufactur ed by TSI, Inc.

Glass Fiber Gauze - The glass fiber gauze was embedded .in themastic coating to provide reinforcement. The gauze was 12 in.wide and weighed 1.70 oz per sq yd.

Mastic Sublimin Coatin — The mastic subliming coatingmaterial was manufactured by TSI, Inc. (and designated Thermo LagType 330, The coating material was supplied in 55 gal steeldrums. The mastic coating is*presently Classified by Under wr itersLaboratories Inc. under Follow-Up Service. The composition andother properties of the mastic coating are considered proprietaryand are on file at the Laborator ies.

PROTECTION OF TEST ASSEMBLY:

The steel column was protected by workmen in the employ ofthe submittor under the obser vation of members of theLabor ator ies'taff.

The column surfaces were wiped with a solvent to removesurface contaminates. The primer was sprayed onto the columnusing an air gun.

The mastic coating, which wa's supplied in steel drums, was.spray-applied to the column surfaces using. equipment designed forsuch purposes.

File R6802-6A Page 2 Issued: 6-5-78

The -mastic coating was applied to the column in several coatsat thicknesses of approximately 1/32 to 1/16 in. Each coat wasallowed to become tacky befor e the following coat was applied.

. After the coating. had been .-prayed to an approximate thickness of13/32 in., the glass f iber gauze was pr essed into the coating overthe entire column with adjacent sections of the gauze overlapped 1

to 3 in. The gauze was lightly rolled with a paint roller .Approximately 3/32 in. of additional coat'ing was then applied tothe column.

The coating was applied to a wet film thickness ofapproximately 1/2 in. as determined by several measur ements takenafter spraying had been completed.

r The wet and dry densities of the mastic subliming coatingwere determined by applying the mater ial at a repr esentativethickness to a 2 by 2 ft steel plate. The wet density wasobtained by weighing the plate immediately after spraying and thedry density was determined using the air dried constant weight oft'e steel plate and coating. The average wet and dry densities ofthe mastic coating were 85.8 and 61.2 pcf,

respectively.'hile

the mastic coating mater ial was curing, severalcrack'aryingin width from hairline to 1/8 in. formed at the

intersection of webs and flanges of the column. These cracks wererepaired nine days after the spraying had been completed.

The final dry film thickness of 15/32 in. was determined onthe basis of 108 measurements taken on the column 40 days afterthe spraying had been completed and the material had dried at r oomtemperature to a constant weight condition. Individual thicknessreadings varied fr om ll/32 to 19/32 in.

The appearance of the column assembly before the fireendurance test is shown on ILL. 2.

GDP/8MB: plh

File R6802-6A Page T1-1 Issued: 6-5-78

TEST RECORD NO.

FIRE ENDURANCE TEST:

This test was conducted in accordance'ith the Standard ofUnderwriters Laboratories Inc. for Fire Tests of BuildingConstruction and Mater ials, UL263 (NFPA No. 251, ASTM E119) .

DESCRIPTION OF SAMPLE.

Prior to placing the column assembly in the furance, severalcracks were observed in the mastic coating at each web and flangeintersection. These varied in width from hairline to 1/16 in. andwere 1 to 2 in. long.

METHOD

The column was placed in the furnace and exposed to flames ofcontrolled extent and severity in accordance with the StandardTime-Temperature Curve. Eight thermocouples, distributed aroundthe column in two levels as shown on ILL. 3, measured thetemperatures in the furance chamber.

The temper atur es of the steel column were measur ed by 14ther mocouples located as shown on ILL. 4. Thr oughout the test,obser vations wr e made to note the character of the fire, thecondition of the exposed sur face of the column, .and all other datapertinent to the fire resistance performance of the column.

Character and Distribution of the Fire - The furnace fire wasluminous and well distributed during the test, and thetemperatures recorded in the furance chamber followed the StandardTime-Temperature Curve as defined in the Standard for Fire Testsof Building Construction and Materials, UL263, and as shown onILL. 3.

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File R6802-6A Page T1-5 issued: 6-5-78

Occur r ence OfLimiting Temperature,

Min + ~

I

Re ortR6802-3R6802-4R6802-6A

77127172

5/321/4

15/32

A summar y of the column test results included in thisengineering evaluation is shown below:

Hater ialThickness,

In.

+ -'Limiting aver age cross-sectional temper ature of1000 F used.

To deter mine the thickness of the mastic coating r equir ed forthe 3 hr rating, a computer analysis of the above materialthicknesses and time to reach the limiting temperatures wasobtainyd. Based upon the resulting equation, Y = 0.00047 1 xit was determined that a minimum thickness of 1/2 in. would afforda 3 hr rating. The test data and the plot of the equation ar.eshown on ELL. 6.

A safety factory of 8 percent (14 min) was used to determinethe above thickness since the equation is an extrapolation of testdata.

GDP/RMB

File R6802-6A Page Cl Issued: 6-5-78

CONCLUSIONS

The following conclusions represent the judgement ofUnderwr iter s Laborator ies Inc'. based upon. the results of theexamination and tests conducted in the Report, as they relate toestablished principles and previously recorded data.

FIRE RESISTANCE PROPERTIES:

It is judged that a 1/2 in. thickness of mastic coating,applied as described in this Repor t will afford a 3 hr rating whenapplied to a stc uctural steel column whose size is equal to otgreater than a W14X228 with- a minimum flange thickness of1-11/16 in., a minimum web thickness of 1-1/16 .in., and a minimumcross sectional area of 67.06 sq in.

The assembly, in summa ized form as shown-:. on the individualdesign illustration included in this Report, will be illustratedin the Fire Resistance Directory as Column Design No. X611.

This Classification is based on the temperature limitationsof 1000 F average and 1200 F maximum. allowable as'escribed underthe ",Conditions of Acceptance" for structural steel columns of theStandard of Underwriters Laboratories Inc. for Fire Tests ofBuilding Construction and Haterials, Standard UL263 (ASTH E119,NFPA No. 251).

The mastic coating and glass fiber gauze of the type used for, this investigation can be readily applied to steel columns by

exper ienced workmen using proper equipment. Materials andspraying procedures .in accordance with those described in thisReport are significant factors in the fire resistance- of thisconstr uction.

CONFORMITY:

This construction was tested in accordance with the Standardfor Fire Tests of. Building Construction and Materials, UL263 (ASTHE119, NFPA No. 251).

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File R6802-6A Page C21'ssued: 6-5-78

FOLLOW-UP PROGRAM:

The mastic coating as descr ibed her ein is cur r ently coveredunder the Classification and Follow-Up Service of Unde>writersLabor atories Inc. Under the Ser vice, the manufacture er isauthor ized to use the Laboratories'lassification Marking on suchproducts which comply with the Follow-Up Service Procedure andany other applicable requirements of Underwriters LaboratoriesInc. Only those products which properly bear the

Laboratories'lassificationMarking are considered as Classified byUnder writers Laboratories Inc.

The Classification Marking used on the mastic coating isillustrated, below:

UNDERWRITERS LABORATORIES INC. R

CLASSIFIED

MASTIC COATINGSFIRE RESISTANCE CLASSIFICATION

DESIGN NO. X611

SEE UL FIRE RESISTANCE DIRECTORX

M14X228 STEEL COLUMN

k4

t

GLASS $'IBER GAUZE

TYPE 330 ISTIC COATS'AGAPPLXED TO A DRY FXLMTHXCKNZSS OF 19/32 XN.

XLL.1R~8C2--6A

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RES ESTANGE RATlNQSXoll A CARD

DESXGN NO. X611

RATING-3 HR.

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R 6802-6A

IGuide BXUVFire Resistance Ratings

June 5, 1978(X611-B Car d)

(Continued From X611-A Card)

I'astic Coatin s» - Coating mixed thoroughly and spray appliedin sever al coats for a dry film thickness of 1/2 in. tocolumn surfaces which must be free of dirt, loose scale andoil. Column sur faces to be pr imed with a modified alkydpr imer'. Glass fiber gauze (Item 2),pressed into coatingprior to application of final coat and lightly rolled inplace with a paint roller. Coating may shrink causing cracksdur ing cur ing. These cr acks shall be filled with additional

- mastic coating.

l TSl Inc. - Type 330. investigated for exterior and inter ioruse. For'xterior use, Type 350 top coat to be applied overmastic coating at a r ate of approximately 150 sq ft per gal.

r 2. G1-~ "s Fiber Gauze - Nominally 12 in. wide, 1.~70 oz per sq yd.E:mbedded in mastic coating around entire col,'umn.

Steel Column - Hinimum size of column a MlNX228, with outsidedimen-ions of 16 by 15-7/8 in., a- flange thickness of1-11/16 in., a web th'ckness of 1-1/16 in., and a cross-sectional area of 67.06 sq in.

Bear ing the UL Classification Har king.,

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File R6802-6A Page C3 Issued: 6-5-78

Repor t by:G. D. PALIKIJEngineering AssistantFire Protection Department

Reviewed by:r

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~~~p'~~.o v.cc

R. M. BERHINIG (Engineering Group LeaderFir e Pr otection Depar tment

SUBMITTED BY:

GDP/RMB:plh

G. T. CASTINOManaging EngineerFir e Pr otection

MONSAiITO MASTIC FL'3.YA ETUNNEL TEST REPORT

The Insulative Performanceof Experimental Formulations

of Subliming FireRe s is tant Coating 33 C -1

A re ort re ared for: ~

TSI ~ Inc.3620 Brannon AvenueSt, Louis, Missouri 63139

Special Report 8008

- Date of Test: March 16, )973

Monsanto Industrial Chemicals CompanySpecial Chemical SystemsResearch and Development DepartmentSt. Louis, Missouri 63)66

Prepared bye D G. Schneider

The information contained herein is true and accurate to the3est of our knowledge and belief, but is transmitted withoutguarantee since the conditions of use are beyond our control.Monsanto Industrial Chemicals Comoany disclaims any liabilityincurred in connection with the use of this information.Furthermore, nothing contained herein shall be construed asa recomzr.cndation to use any product or practice any processin conflict with any existing patents covering any material orits use+

TABLE OF CONTE~aS

Pa e Ão.

INTRODUCTI'ON ~ ~ e ~ ~ ~ e ~ ~ e ~ ~ ~ ~ - ~ ~ I-I

SUMMARY ~ a ~ ~ ~ ~ ~ a ~ ~ e ~ ~ ~ ~ ~ ~ ~ ~ II-I

DETAILS . ~ ~ ~ ~ ~ ~ ~, ~ ~ ~

Subliming Fire Resistant Coating 330-1,Formulation No. 02131L on Large Beaxn,Nominal 350 mil Coating

~ ~ ~ ~ IIX-I

Table Ible I ~ ~ ~ ~ ~ ~, ~ ~ Observation NotesFigure 1 ~ ~ ~ ~ ~ ~ ~ ~ ~ .Sample and Furnace

Tempe rature ProfilesFigure 2 ~ ~ ~ ~ ~ + ~ ~ Q Sample Illustrations

IV MONSANTO MASTIC TES'XING FURNACE ~ ~ . ~ ~ IV-

I~ INTRODUCTION

This report describes the insulative performance of experimentalformulations of subliming fire resistant coating 330-1 @(hen testedin a small furnace according to the time/temperature conditionsdescribed in ASTM EL19-67 ~

This. small Monsanto furnace test is intended to be used as ascreening device for the development of insulative coatings. It isnot intended to displace the large furnace test or evaluation ofprop'osed products by recognized testing laboratories.

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SUMMARY

The coating was applied to a sandblasted carbon steel (ASTRA-52)column. The column was fabricated from two I»beams~elded togetherto form a hollow rectangular core. The coating was applied and driedby TSI personnel before being submitted for testing.

The test column was subjected to the time/temperature conditionsspecified in ASTM E119-67 using the Monsanto furnace. This furnace

„is a modified version of the larger ASTM E119-&7 test furnace.Substrate (steel column) temperature is monitored by six continuously

'ecording the rmocouples within the column core. These thermocouplesare spaced at even intervals along the column length from S" to 38"from the bottom of the specimen.

A performance rating of 172 minutes was obtained for the test specimenon February 24, 1973 (see Table I for the Test Observation Notes).Performance ratings are, in fact, the length of time between furnaceignition and the atta nment of,a 1100'F (593'C) substate temperature. Atthe time of failure, only one of the six substrate thermocouples had reachedthis temperature. The furnace and sample temperatures recorded duringthis test are illustrated in Figure 1. Figure 2 illustrates the condit:on ofthe specimen before and after testing

+Fabricated from 10-inch beams, modified and weldect to fora@ arectangular core of 10" x 5-1/4" x 40"

ITA BLE I

OBSERVATION NOTES: Subliming Fire Resistant Caating 330-1,Formulation OZ131I on Large Beam,Nominal 350 mil Coating

Minu'.es Observations

14.

P '

Upper half of cyluma beginning to darken with intumescence.

Ci. 1/8" of intumescence... some blisters.

Some surface Gaming (quasi-halo effect).

Intumescence 1/4"-1/2" thick and plastic, teznperature rise ca. 6 C/mine

Intumescence 1/2"-3/4" thick and.elastic/plastic, surface flamincontinues, temperature rise ca. O'C/xnia.

51

Surface beginning to whiten,

Surface skin has become plastic/tough(rubbery) ~

Temperature zise ca. 4 C/min., intumescence 3/4"-I I/2" thick,skin is crushable (aot too hard), surface Gaming is lower, now

Surface nearly all white, and surface skin Cough/hard. Tem eraturerise ca 3'C/min.

~ empera ure

83

101I

I I 11

121

128

141

150

Intumescence 1 1/4'~-? 1/4" thick and surface is hard (crushable).

Intumescence is ) 1/2"-2 1/2" thick (softer in flaages than on flats f)Temperature rise ca. 2 'C/min.

Intumescence layer thickness unchanged, but it is softeain .rise 1 C/min~

~ ea ng. eznperature

~ Intumescence 2 1/4"-3 1/2" thick(soft). Flange edges are thicMycovered with intuznes cence

Intuznescence? 1/2' - 4" thick

Intumescence 3"-5" thick, temperature rise ca. 2'C/znin.

The surface layer of intumescence has falIea aff of ca. 1/3 of the westside (not serious though siace it was anly ca. 1/?" !hick)~

Iatumescence is unchanged, temperature rise ca. ? 1/? 'C/znin

Surface is degrading still xnore (aot serious though) ~ temperaturerise ca. 3'C/min.

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TABLE K (Continued

M/nutes

159

163

172

Obs e rva tions

Large portion of intumescence fell away from top west siderevealing a few sq. ia. of steel substrate, failure is eminent.

26«TC reached 1000 'F,

Failure, 26«TC reached 1100'F.

178 ... 26«TC reached 1200 'F

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B. Close-Up of Burned Specimen

IU, MONSANTO MASTIC T STING r LB.NAC™

Monsanto Industrial Chemical Company's mastic testing furnace ii amodified version of the larger ASTM E119-67 test furnace used byUnderwrite r's Laboratories.'he furnace chamber ( 35" x 35" x 43")contains a volume of ca. 30 ft~. Each of the four waLls has three gasburners, which are regulated to yield the standard time/temperaturecurve described in.ASTM E119-67. The furnace temperat re is indicatedby eight thermocouples located within 1-Z" o: the sample spec'.men.Sample temperature is monitored. by six thermocouples touching the

~ metal substrate below the protective coating.

Attempts to correlate this furnace test with the ASTM E119 furnacehave indicated that the Monsanto testing furnace ~ma be slightly moresevere, Additional data is required to statistically define this correlation,however.

A more complete descr''ption of the Monsanto testing furnace willbe thesubject of a paper which will'be prepared and published in the near future

I

-JI

Factoi"y,Mutual Reseals chl

~ ~ 4 ~ ~~ >g>r 4

E EXPLORATORY

PIRE E%)URANCE TEST

OlL-

STRUCTURAL STEEL COLUMN,J

I!

with'i '

'i!

THERIAC-LAG 330-1 COATD4G '.'i

fox'JP 1

li

TSX,IN'260

BRAiPiION AVEi

ST+ LOUIS,: MO. 63139

SERIAL NO. 23187

CLASS NO. 4

NOVEMBER 30~

970

1973

I

GENERAL

This reports results of an exploratory fire test conducted in the Factory MutualHigh Temperature Furnace.

I The ob)ect of this test was to determine what protection the manufacturer'scoating would afford t'o steel beams when exposed to temperatures noted below.

The test member was a 31 in. long W14 x 220 steel beam coated with Thermo-Lag330-1. Thermocoupling and coating of the beam was done by the manufacturerat his plant and delivered to Norwood for test.

The tests were not conducted in accordance with any standard test method. Themanufacturer requested the beams be exposed to a time temperature curve havingthe following characteristics: 0 min. ambient, 5 min. 1000'F, 10 min. 1300'F,15 min. 1399'F, 30 min. 1550'F, 1 hr. 1700'F, 2 hrs. 1850'F and 3 hrs. 1925'F.

SAMPLE PREPARATION

Six thermocouples were peened into a 14W x 220 steel beam. All were imbedded1/4 in. Four into the 1-5/8 in. thick flanges and two into the 1 in, thickweb. Those in the flanges were located less than 1 in. from the web. See

Appendix A for locations.

The bottom and edges of the bottom flange were coated by the manufacturer witha hard surfaced white material identified by him as Thermo-Lag 330-1 to anaverage dry film thickness of 0.205 in. Remaining surfaces of the steel beamwere unprotected.

FIRE ENDURANCE TEST AND RESULTS

The sample was placed on top of the H4 High Temperature Furnace exposing thecoated surface only to the firing chamber. The remainder of the beam wasexposed to the ambient temperature.

Observations Durin Test:

Five minutes after ignition, intumescense began and white smoke issued fromthe coating. This smoking stopped at,30 min, No significant changes werenoted until 2 hrs. at which time small pieces of intumesced material beganflaking off for the remainder of the test. The flame was extinguished at3 hrs. 1 min.

Furnace and steel temperatures are shown on the attached Appendix B.

~ os\ ~ . ~

Observations After Test:

A few hours after the test, an examination of the beam showed approximately50X of the coating had fallen into the furnace. The coating left was fragileand fell off readily when touched.

CONCLUSIONS

Due to the exploratory nature of this test, and it not being a standard test,no conclusions can be drawn as to the coating's effectiveness.

Si~E/hh.

!

Pro)ect Engineer

t ATTACHrD: Appendices A and B

I

/ /fwx22'g ~dc aj /earn ~ifh I+/8" > hick Chirped, Bl" lang;() 7 herrnoceuple jocund'ionS, AII 14 (n Prom one end oP beam.

8. Thern~ol>Q 930 / j a. SoS' dr y fi.lp thickness.

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Factory Mutual Research ~ ~

EXPLORATORY

FIRE &(DURA FACE TEST

on

STRUCTURAL STEEL COLUiS

with

THERMO-LAG 330-1 COAT Ii'IG

for

TSI,IN'260

BRA'iNON AVE.E

ST. LOUIS, MO. 63139

SERIAL HO. 23187.1CLASS itO. 4970

NOVEMBER 30, 1973

GENERA.

This reports results of an exploratory fire test conducted in the Factory lfutualHigh Temperature Furnace.

The object of this test was to determine what protection the manufacturer'scoating would afford to steel beams when exposed to temperatures noted below.

The test member was a 31 in. long V14 x 220 steel beam coated with Thermo-Lag330-1. Thermocoupling and coating of the beam was done by the manufacturerat his plant and delivered to Norwood for test.

The tests were not conducted in accordance with any standard test method. Themanufacturer requested the beams be exposed to a time temperature curve havingthe following characteristics: 0 min. ambient, 5 min. 1000'F, 10 min. 1300'F,15 min. 1399'F, 30 min. 1550'F, 1 hr. 1700'F, 2 hrs. 1850'F and 3 hrs. 1925'F.

SAMPLE PREPARATION

Six thermocouples were peened into a 14M x 220 steel beam. All were imbedded1/4 in. Four into the 1-5/8 in. thick flanges and two into the 1 in, thickweb. Those in the flanges were located less than 1 in. from the web. SeeAppendix A for locations.

The bottom and edges of the bottom flange were coated by the manufacturer witha hard surfaced white material identified by him as Thermo-Lag 330-1 to anaverage dry film thickness of 0.205 in. Remaining surfaces of-the steel beamwere unprotected.

FIRE ENDURANCE TEST Ai%) RESULTS

The sample was placed on top of the FM High Temperature Furnace exposing thecoated surface only to the firing chamber. The remainder of the beam wasexposed to the ambient temperature.

Observations Durin Test:

Five minutes after ignition, intumescense began and white smoke issued fromthe coating. This smoking stopped at 30 min. No significant changes were .

noted until 2 hrs. at which time small pieces of intumesced material beganflaking off for the remainder of the test. The flame was extinguished at3 hrs. 1 min.

Furnace and steel temperatures are shown on the attached Appendix B.

Furnace< TGMpcpl'kai e

Igloo

0

o 0OOt)-I-

800

I Ge=

(I

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i:

Igloo

II ~/a.

T",me C//>u r5)

SoHew i. IsedC'srgpera0arg

7 SX; ~nC.iSCP oNO. ~/8'/BOkb8W 4/II1]p O4JQ W/g2.0 gy/ ~p~Coak& c if 0~S(dry film thatch ess jc0 v4e~~n- lay )go-(.

Observations After Test:

A few hours after the test, an examination of the beam showed approximately50X of the coating had fallen into the furnace. The coating left was fragileand fell off readily when touched.

CONCLUS IOiiS

Due to the exploratory nature of this test, and it not being a standard test,no.conclusions can be drawn as to the coating's effectiveness.

Slz/hh.

I)

IS.. VM.gh

Prospect

Engineer

AXTACMD: Appendices A and B

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(.) 7 be~rnoce~ple Jocu''ionS. 3II /4 i', Prom one end oP h8887.9. 7'/gal i»otal 930-/

>c)-No5 'ry Ji lm +I~ickness.

7 $,2) >iceSei..4o. PSr8 7 /

UNDER%'RITERS LABORATORIES LiNC.Ql PFINiiTFI RtLEO 'rORBIRRAWi, ILl.l>AS t'r>Wl

an indepenctent, not-for-profit o! <grani ation te8ting Jor public.~afet!t

January 31, 1979

R6802"777NK7340

TSZ, Incorporated3260 Brannon AvenueS t. Louis, MO 63139

Attention!

Subjects

Mr. Rubin Feldman, President

Report On The performance Of A Steel Load BearingWall Assembly protected With a Mastic CoatingDuring Fire and Hose Stream Tests

Dear Mr. Feldmanc

This is a Report on the performance of a steel walL assemblyprotected with a mastic coating during Fire and Hose StreamTests -conducted in accordance with Standard UL 263, titled"Fire Tests Of Building Construction and Materials."

The test assembly consisted of a 1/2 in. thick steel platewith a WT18X85 vertical member and three NT6X18 horizontalmembers positioned as shown on ILL. 1 ~ The assembly wasprotected on all surfaces with a Classified mastic coatingdesignated Type 330, manufactured by TSI, Inc.

DESCRIPTIONMATERIALSt

The materials used in the test assembly are describedbelow.

Bearin Plate - The steel bearing plates were 15 in. videby 9 t, n. ong by 1/2 in. thick.

Su rt An les - The support angles vere 3 by 3 by 1/2 in.thick stee ang es 36 in. long.

iL'ADER'l'VR(TERS LABORATORIES t.iC.

R6802-7Page 2Jan. 31, 1979

Prefabricated Mall Assembl - The prefabricated wall assemblywas a we ed stee section cons sting of a 10 ft by 10 ft by1/2 in. thick steel plate with a NT18X85 vertical member and threeNT6X18 horizontal members.

Primer - The primer vas a two-part inorganic zinc richmateriaT~esignated 90-92E manufactured by Tnemec Company, Inc.

Reinforcement - The reinforcement was a 12 in. vide glassEtb ~ig1.70 * qy

Mastic Coatin - The subliming mastic coating material wasmanufacture y TSI, Enc. and designated Thermolag Type 330. Thecoating material was supplied in 55 gal steel drums. The formula-tion and other details concerning the manufacturing of the coatingare on file at the Laboratories for use in connection with theFollow-Up Service Program.

ERECTION OP THE TEST ASSEMBLY:

The assembly vas iristalled by workmen in the employ of thesubmitter under the obse'rvation of members of the

Laboratories'taff.

The appearance of the assembly during the installationis shown on ILL~ 2.

The steel bearing plates were attached to unistrut channelslocated in the sill and lintel of the test frame. The wallassembly was positioned in the test frame opening and the supportangles were attached to the unistrut channels through the bearingplates. The assembly was then attached to the support angleswith 5/8 in. diameter machine bolts and nuts. The assembly wasattached to each support angle vith three bolts.

i The wall assembly was sand-blasted to remove surface rust andother contaminates and then coated vith the primer ~

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4'NDERA'R(TERS (.ABORATORlES INC.

R6802-7Page 3Jan. 31, 1979

The mastic coating was spray-applied to all surfaces of theassembly in a multi-coat procedure to approximately 75 percent ofthe final thickness at which point the glass fiber gauge reinforce-ment was applied over the entire surface, The coating was thentrowel-applied over the reinforcement to the final design thickness.

The coating thickness was measured after the coating had driedapproximately four weeks. -A summary of these measurements arecontained in Table I.

TABLE I

Location

Number Of Minimum Maximum AverageMeasure- Thickness Thickness Thickness

NTlSX85

NT6X18

35

32

16 26

28

18.6

19.0

481/2 in. plateexposed surface

1/2 in. plateunexposed surface 69

11. 5 20 16.1

'20.5 14.8

The appearance of the exposed surface of the assembly priorto the Fire and Hose Streaa Tests is shown on ZLI. 3.

R6802-7Page 4Jan..31, 1979

TEST RECORD NO ~ 1

FIRE ENDURANCE TEST:

This test was conducted in accordance with the Standard ofUnderwriters Laboratories Inc. for Fire Tests of BuildingConstruction and .Materials, UL 263 (NFPA No, 251, ASTM E119) .

DESCRIPTION OF SAMPLE

: The assembly was constructed as described in the precedingsection of this Report titled "Erection of Test Assembly" andas shown on ILLS. 1 and 2.

METHOD

The wall assembly was placed in front of the panel fuxw".coand exposed to flames of controlled intensity anQ severity

ia'ccordancewith the standard time-temperature carve. Twelvethermocouples, distributed as shown on ILL. 4, measured thetemperatures in the furnace chamber..

The temperatures on the unexposed surface of &e c ssemblywere measured with nine thermocouples, with each thermocouplecovered with a 6 by 6 in. dry asbestos pad. The thermocouploswere located as shown on ILL. 5.

The temperatures of the HTLSX85 vertical member weremeasured with twelve thermocouples located ar. shown on ILX. G.

The temperatures of the HT6X18 'horizontaL members veremeasured with nine thermocouples located as shorn on ILJ'i..7.

The temperatures of the 1/2 in. thick steel pEate at; dieinterface of the coating material applied to the expos'a'.c" avrf!aceof the assembly were measured with nine thermocouplee Lnca<e-',

ao'hownon ILL. 7.

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IR6802-7Page 5Jan. 31, 1979

The lateral deflections of the assembly were determined by

Lmeasurements taken at the quarter and centerpoints along the-horizontal centerline of the unexposed surface. The referenceline was a taut steel wire.

A compressive load of 100,000 Lb was applied on the assemblyby means of seven hydraulic )acks. The magnitude of the load wasspecified by the submitter.

.The vertical movement of the loading beam was measured bytwo ex~nsometers placed near the north and south quarter pointsof the assembly.

Throughout the test, observations were made to note thecharacter of the fire and its control, the condition of theexposed and unexposed surfaces and all developments pertinent tothe performance of the assembly with particular reference to thestability, heat transmission, passage of flame and generation ofsmoke.

RESULTSi

t Character and Distribution of Fire - The fire was luminousand we xstr uted, e temperatures developed follow thestandard time-temperature curve, as shown on XLL~ 4 and as

i specified in the Standard.

Observations of the Ex sed Surface - The following observa-tions were ma e urging e re test. All references to dimensionsare approximate.

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l. YDERA'R(TERS LAB()RAT()R!ES ti'C.

Jan. 31'979R6802-7Page 7

Observations of the Unex sed Surface -. The followingobservations were made during t e are test. All referencesto .dimensions are approximate.

Test Time,Observations

10

30',

60

85

Small amount of smoke is rising from the top of theassembly.

No ma)or changes observed.

Small a~unt of smoke is rising from the surfacenear Thermocouple No. 4. This smoke appears to beescaping through holes in the coating made duringthe coating thickness measurements.

Small amounts of smoke rising from various points onthe surface.

120

140

145

160

The amount of smoke rising from the surface isincreasing.

The coating is bowing outward near the lower northportion of the assembly.

The coating is bowing outward at several locations.

The amount of smoke rising from the surface continuesto increase.

181 Pire test terminated.

I '

R6802-7Page g

t Jan. 31, 1979

!

Deflection - The horizontal deflection of the assembly~ 8 e ' \ bl

TABLE IIHori,zontal Deflection - Inches

Test TimeMin

0102030405060708090

100110120130140150160170180

OU

01/81/41/41/43/85/81/23/83/81/25/85/8

05/8»]»

7/8*5/8*5/8»

Locationenter

01/83/41/81/81/81/81/81/81/83/8-3/81/41/41/81/81/81/81/8

Net

01/8*5/8»3/8»3/8*5/8»3/4*

1-1/8»1»1/8*1-1/8

7/8*7/8*

1-3/8»1-3/8*1-5/8»1-5/8»1-7/8*

2»2-1/8*

* - Indicates movement away from the fire. All otherreadings indicate movement towards the fire.

R6802-7Page 9Jan. 31, 1979

The vertical deflection of the loading beam measured duringthe fire test is shown in Table IIX.

TABLE IIIVertical Deflection - Inches

Test Time,Min Sout

Location

0102030405060708090

100110120130140150160170180

00.00340.002*0.008

- 0.0270.0450.0650 ~ 0850.1050 1270.151

. 0.1810.2000;2270.2520.2800 '050 '380.365

00.002*0.0010.013-0.0320 '520.0730.0940.1160.1390.1660.1980.2200 '500.2800 '100.3400.3750 '05

* - -Indicates upward movement. All other readings indicatedownward movement.

III

R6802-7page 10Jan. 31, 1979

Tem eratures of the Assembl - The initial averagetemperature o the unexpose sur ace was 77 P. Therefore,based on an average temperature rise of 250 P above ambientand a maximum individual rise of 325 P above ambient< theaverage limiting temperature was 327 P and the individuallimiting temperature.was 402 P.

The'temperatures of the unexposed surface are shown onILL. 5. The average limiting temperature occurred at 138 minand the individual limiting temperature occurred at 160 min.

The temperatures of the WT18X85 vertical member are shown'n ILL. 6 for general information purposes. At, 180 min, themaximum average cross-sectional temperature was 955 P and themaximum individual temperature was 1070 P.

The temperatures of the N6Xl8 horizontal members are shownon XLL. 7 for general information purposes. At 162 min, themaximum average cross-sectional temperature was 1000 P and at168 min, the maximum individual temperature was 1200 P..

I

~-=—--The. temperatures of the X/2 ii. thick steel-plate~measured,,at the interface.",of'he;coating. material apgied, on'the"exposed;,.;"-:,.surface of the assembly and the. sted. plate are'hown on. ILT',V."<for- general: informati.on. purposes- 'At 180=min~, the average;--:-;-.;.„'..

Itemperature"waa V3$' and; the,maxhaum individual--temperature: wa'g,

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L'ADER'L'FR[TERS LAB'OftkTOR[ES IYC.

Immediately. after the fire exposure, the assembly was with-drawn from the fire and the exposed surface was sub)ected to theimpact> cooling and eroding action of a water stream app1ied witha 1-1/8 in. nozzle at 30 psi pressure from a distance of 20 ft fora period of 2-1/2 min.

R6802-7page llJan. 31< 1979

HOSE STREAH TESTc

During the Hose Stream Test, the coating material applied onthe exposed surface was eroded away. The remaining portion of the

.assembly remained in place and the hose stream did not penetratethrough the assembly.

OBSERVATIONS AFTER THE TESTS!

The appearance of the exposed and unexposed surfaces ofthe assembly after the tests are shown on "ILLS. 8 and 9,respectively.

P

On the exposed surface, the coating material applied to the1/2 in. thick steel pl'atc and the exposed flanges of the NTLSX85and NT6X18 members was eroded away from the steel surfaces duringthe Hose Stream Test. The coating materiaL remained on the websand inner fLange surfaces of the NTLSX85 and WT6XLS members.

On the unexposed surface, the coating materiaL delaminatedfrom the steel plate in many areas, resulting in voids betweenthe coating material and the pLate. The maximum depth of thevoids was approximately 2 in. The color of the coating materialwas darker underneath each asbestos pad as compared to the .

remainder of the material on the unexposed surface.

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L'iDFRiVR(TERS LABORATORlES lb'C.

R6802-7Page 12Jan. 31, 1979

I S UMHA RY

I Because you do not desire a formal Report to be publishednor the tested assembly to be Classified in our Pire ResistanceDirectory, we are closing Assignment 77NK7340 with this Reportand instructing our Accounting Department to invoice you for thefinal charges.

Very truly yours,

maZROBERT Mo BERHINZGEngineering Group Lea rPire Protection Department

Reviewed by<

~J glgga!!~88(Ko W, HOWELLAssociate Managing EngineerPire Protection Department

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an inrtepenclent, not-for-profit o> gani:ation testing for public safety

April 1, 1981

R680281NK4969

TSI, Inc.3260 Brannon Ave.St. Louis, MO 63139

Attention: Mr. Rubin .FeldmanPresident

Subject: Exploratory Small-Scale Fire Test

Dear Mr. Feldman:

This letter will confirm that an exploratory small-scalefire test has been conducted on a test sample consistingof a 5/8 in. thick steel plate covered with two layers of1 in. thick rigid fiberglass form boards and 0.3 in. ofType 330 mastic coating. A fiberglass cloth, weighing1.70 oz per sq yd was embedded in the mastic coating.

The test was conducted to provide TSI, Inc. with unexposedsurface temperature data to help evaluate the above productsfor future ULI Classification.The unexposed surface temperatures of the small-scale samplewere measured by ten thermocouples, each of which wascovered by a 6 by 6 in. dry asbestos pad. The thermocoupleswere installed by a representative of TSI, Inc.The furnace temperatures, as measured by three symmetricallylocated thermocouples placed 12 in. below the exposed surface,followed the Time-Temperature Curve, as outlined in StandardUL 263.

The limiting average unexposed surface temperature (321 F)occurred at 228 min (3 hr, 48 min). The limiting individualtemperature (396 F) occurred at 272 min (4 hr, 32 min) .The fire test was terminated after 300 min of exposure.

Look For The @Listing or Classification Mark On The Product

UiNDERA'RITERS LABORATORIES INC.

R6802April 1, 1981Page 2

We have enclosed the unexposed surface temperatures representedboth graphically and in tabular form.

This letter 'completes our anticipated work on Assignment81NK4969 and we have instructed our Accounting Departmentto bill TSI, Inc. for the charges'ncurred.

Very truly yours,

L L Y@~ ~ -:Lb .till,.GERALD D. PALIKIJ ~J

Senior Engineering AssistantFire Protection Department

Reviewed by:

B. SWYTNYKEngineering Group LeaderFire Protection Department

GDP:pr

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W W W W W W W W W W W W W W W W W WUNEXPOSED SURFACE TEMPERATURES

TSI, INCORPDRATED

DEGREES, F

NNINI IML

TBPEfQTURE

AVERAGE

TEHPERATURE

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230235240245250255260265h70275280285290295'0

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TABLE NO. 1

98.8102. 1104. 5106. 9109. 3111. 7114. 3117. 2120124 2128. 1132. 2136.6141.1146.151.156. 3ibi. 6167. 1172. 8179186. 2193. 8201. '7209. 8217. 6225232. '7

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" 245. 3253.3260. 8Z67. 9274. 7281. 1287. 129Z

9'98.3303. 5308.4313.1317. 5321.632S. 4329332.5336. 1339. 4342. 7346. 1349. 5353356.3359.9363. 2366. 5

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THREE. HOUR FIRE ENDURANCE TESTS ON

TSI'S CONFORMABLE THERMO-LAG 330 -STRESS SKIN

FIRE WALL ASSEMBLY

PRELIMINARY REPORT

JUNE 1981

TSI, INC. 4 3260 BRANNON AVE. 4 ST. LOUIS, MO. 63139 ~ (314) 352-8422 4 Telex'-44-2384

THREE HOUR FIRE ENDURANCE TESTS ON

TSI'8 CONFORMABLE THERMO-LAG 330 STRESS SKIN

FIRE WALL ASSEMBLY

GENERAL:

This reports the results of a fire simulation test conductedat TSI's ASTM E119 Fire Simulation Facility. The objectiveof this test was to determine the degree of fire resistanceto flame penetration protection offered by TSI's THERMO-LAG

330 Conformable Stress Skin Fire Wall Assembly.

FIRE TEST AND RESULTS:

The test member was 4'ong x 4'ide. The Stress Skin wascentrally located with 0.695 inches of THERMO-LAG 330-1Subliming Coating on the fire and non fire side. Theinstrumentation of the test articles consisted of 9 thermocouplessymmetrically located on the exterior surface of the no flameside of the test assembly. Each of the thermocouples werecovered with 6" by 6" dry asbestos pads'he facility tempera-ture was measured by 9 symmetrically located thermocouplesplaced 12" away from the exposed surface of the test assembly.The limiting temperature of the unexposed surface of 320'F

occurred at 207 minutes. The limiting individual temperatureoccurred at 220 minutes at which time the fixe test was

terminated. Visual observations during the test have clearlyshown that there was no penetration of flame through the testassembly at any time during the fire.

The test procedure followed prerequisites of ASTM E119 Time/Temperature Environment and IEE 634 entitled IEE Standard CablePenetration Fire Stop Qualification Test. This is a preliminaryreport. A detailed report is being prepared and will be submittedshoxtly.

I'

~ ~ ~ g~ ~

g ( ) ~ ~ERR5 ~ 'EESWRES e gMRMMEEMRRWS,RRE8$ 588855885 .'8i$888858$ 8858 8888,MRRRM555 SS 855SR555MMSRS 85 MEERRS'SRE55555RSR S RQSRRR855 EE5555E $5555ESW~ RRRRRR 8 RRRR5$ 55555„55M55 55555$ 5555555k555 S RSSERRWSSMRRSS

, %SR 55555W5$ 55555555'MSQEikiM5$555S5$ 55$,5155 S$ 55555555555k5

ASTM E119-73 FIRE ENDURANCE TEST (MODIFIED)

STRUCTURAL STEEL COLUMN PROTECTEDBY 'Q|ERMO-LAG 330-1 COATING

DESIGN CT-36

for

T.S.I., INC.3260 BRANNON AVENUE

ST. LOUIS, MISSOURI 63139

SERIAL NOo 23160.1(CLASS FILE 4960)

APRIL'974

iFactory Mutual Research1151 Boston- Providence TurnpikeNorwood, Massachusetts 02062

SECTION II

SIMULATED POOL FIRE TEST

ON

THERMO-LAG COATED PLATE'

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SECTION III

SIMULATED POOL FIRE TEST

ON

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SECTION IV .

SIMULATED POOL FIRETEST'N

THERMO-LAG COATED PLATE

1/4 INCH

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98.269

SECTION V

FULL SCALE TANK CAR TESTS

tsr

~r0~~ALIIS 0S

DEPARTMENT OF TRANSPORTATtONFEDERAL RAILROAD ADMINISTRATION

WASHINGTON, D.C. 20590

gUN 24 19T7

Dr; Rubin FeldmanPresident, TSI'nc.3260 Brannon AvenueSt. Louis, Missouri 63239

Dear Dr. Feldman:

In response. to your request for torch data generated on a tank carequipped with nominally. 165 mils of your material, I'm enclosing:.

a) Data from a bare tank car torch test.

b) Full Scale Torch Test 'data on TSI - coated tank car (nominalthickness 165 mils--August 25, 1976).

If you have any questions regarding this data, please feel free .tocontact me.

Sincerely,

n LevineChief, Rail Vehicle SafetyResearch Division

Enclosure

SECTION VI

BARE TANK CAR TORCH TEST

BRRE TRNK CRR: . TEST 43

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DOT FIRE HOSE WATER IMPINGEMENT TESTS

DOT FIRE HOSE WATER IMPINGEMENT TESTS

4

DOT FIRE HOSE WATER IMPINGEMENT TESTS

I~cicely Mutual Big,seal ch

!

1151 Boston-Providence TurnpikeNorwood, Massachusetts 02062

i 23160.1 April 1974

ASTM E119-73 FIRE ENDURANCE TEST (MODIPIED)

STRUCTUEVJ STEEL COLUMNPROTECTED BY THERMO-LAG 330-1 COATING

e

i11

li

DESIGN CT-36

for

T.S.I., INC.3260 BRANNON AVEZRE

ST. LOUIS, MISSOURI 63139

GENERAL

This report describes the construction, the test procedure and the results ofa fire endurance test conducted on a W10x49 structural steel column protectedby Q.217 in. thickness of Thermo-Leg 330-1 coating as shown on Illustrationl.

2 ~

The object of this test program was to determine the performance of a columnmember protected by a coating conforming in quality and physical propertiesto those herein described. A fire endurance test was conducted on the protec-ted column member under steel temperature limitations in accordance with theStandard for Pire Tests of Building Construction and Materials ASTM Designa-tion E119-73, (NFPA No. 251) with the following exceptionss

1. The 5 ft. length of the column tested was less than the required 8 ft.Two levels of four thermocouples were used to monitor the temperature ofthe steel column in lieu of four levels of three thermocouples.

The test was conducted at National Gypsum Company using their furnace designto meet the requirements of the ASTM E119 Standard for the evaluation offloor-ceiling assemblies. The height of the column tested wae restricted dueto the depth of the furnace chamber.

I

The column assembly was subjected to a fire exposure for a duration of 2

hours and 8 minutes.

III

I

I

Page 2

FACTORY MUTUAL RESEARCH CORPORATION

23610 1

DESCRIPTION

The materials used in the construction of the protected column assembly aredescribed below:

Column — The steel column was a W10r49 struotural member 5 ft. 6 in. long andwhen installed in tha furnace hed an effective length o! 5 ft .as measuredfrom the furnace floor to the underside of the concrete cap. The concretecap was 5 in. thick by 20 in. square. The cross-sectional dimensions of thecolumn were 10 by 10 in. with 9/16. in. thick flanges and 3/8 in. thick web.

„~Cootie - The coating material was manufactured by Tgl, Inc. snd designatedas Thermo-Lag 330-1. The product is a water base intumescent coating materialof subliming characteristic. The material was furnished ready for usesThermo-Lag 330-1 was supplied in 55 gal. containers snd weighed approximately9 lbs/gal.

Coatin Reinforcin - Glass fiber mesh 28 in, wide stzips cut 24 in. longand weighing 1.88 oz/yazd. The mesh was wrapped completely around ths columnfollowing its contour being installed between applications of the Thermo-Lag330»1 coating.

PREPARATION Op COLUMN ASSEMBLY:

Eight thermocouples were attached to the steel column, four at each level asshown in Illustration 5. The wire, used for the thermocouples, was No. 20B6S gage iron-constantan with an enamel and felted asbestos insulation.Through holes were drilled in the steel and one lead of the thezmocouple wirewas pulled through until its )unction was at mid-thickness of the steel andthen the steel was peened to close the opening.

The protective coating was appLied as shown on Illustrations 1 through 3.'he column member first received a brush coat of TSI, Inc. 220 Primer appliedat a thickness 0 003 in. and allowed to set for one day. The column thenreceived two spray applied coats of Thermo-Lag 330-1 on two successive dayswhich resulted in a total thickness of 0,160 in. After a one day set period,the column received a brush coating of 330-1 thinned with water to,the oasis-tency of thick paint before applying the glass fiber cloth. The mesh clothwas placed horizontally around the column following its contouz. The ends ofthe strips were butt-pointed at each side of the column web while the sides-overlapped the ad]scent strips 1 in. The mesh cloth covered the entireheight of the column. h second coat of the thinned 330-1 was brushed on.

The next day a third coat of Thermo-Lag 330-1 was sprayed applied. The dryfilm thickness of the overall coating was in exc ss of the desired. By use.of an automotive type body grader, the coating was removed so that theoverall coating was an average of 0.217 in. thick after an additional brushcoat of water-thinned 330-1 was applied.

IIIII

I

I

23160. 1

FACTORY MUTUAL RESEARCH CORFORATIOH

Page 3

FIRE Pi<DURANCE TEST

The test was conducted in accordance with the Standard for Fire Tests ofBuilding Construction and Materials ASTM Designation E119-73 (tPPA No, 251)with the exception that the column was 5 ft. in length and were instrumentedwith two levels of four thermocouples. The Standard specifies a minimumlength of 8 ft. and four levels of three thermocouples. The National GypsumCompany equipment for the testing of flame ceiling assemblies was used forthis test.

SA.PLE:

The column member tested was described under Preparation of Column Assembly.

KTHOD:

The column assembly was placed in the floor-ceiling furnace as shown inIllustration 4 and a fire rated ceiling system was installed over the fullfurnace opening. The temperature of the furnace chamber was measured by 14thermocouples which were placed 4 ft. above the base of the column and loca-ted as shown in Illustration 5. Thermocouples Nos. 9 and 12 did not function.

The temperatures of the steel column were recorded at 8 locations as shown onIllustration 6. The ASTM E119 Standard states the limiting end point tempera-tures are reached when the average temperature of the steel at any one levelexceeds 1000'P or if any single temperature exceeds 1200'P.

Throughout the test, observations were made to note the character of thefire, condition of the column protection, and all other data related to itsfire resistive performance.

I

I

I

IIII

FACTORY MUTUAL RESEARCH CORPORATION

23160.1

CONCLUSIONS

Page 7

A fire endurance test was conducted on a W10x49 structural steel columnprotected by a coating 0.217 in. thick of Thermo-Lag 330-1. The protectedcolumn was sub)ected to fire exposure for a duration of 2 hours and 8 minutes.

The test was conducted under steel temperature limitations in accordance withthe Standard for Fire Tests of Building Construction and Materials ASTMDesignation E119-73 (NFPA No. 251) with the exception that the column was 5ft. in length and was instrumented with two levels of four thermocouples.The Standard specifies a minimum length of 8 ft..and four levels of threethermocouples. The limiting end point temperatures are reached when theaverage temperature of the steel at any one- level exceeds 1000'F or if anysingle temperature exceeds 1200'F.

The protected column assembly as. tested met the requirement of the Standardfor 90 min. after fudging Thermocouples No. 6 and 8, used to monitor steelcolumn temperatures, were functioning improperly.

At two hours of exposure only two 'thermocouples were functioning. The tem-perature measure at this time was 550'R and 595'F. It is Factory Mutual'sopinion based on the condition of the coating that had the thermocouples notdeteriorated, this column assembly as tested would had satisfied the require-ments for two hours.

LABORATORY RES PONS IBILITY

The Factory Mutual Research Corporation makes no )udgement of product uniformitysolely as a result of the ASTM E119 fire tests. Product uniformity depends inpart on manufacturing facilities and procedures which would be inspected byFactory Mutuals Quality Assurance Follow-Up Inspection Program and on a writtenagreement put in force between both the product manufacturer and Factory Mutual.

Unless these conditions are met, the product can not bear the Factory Mutual namein its advertising.

Page .8 FACTORY MUTUAL RCSEARCH CORPORATION 23160.1

ILLUSTRATION 1

I/ ~

~10 <49~ygpg CL.uMH

1 HKRMO - LAG.C04>L l4G 330 - I

GLASS FtSKR CLOTH/

0.2) 7

Avgas

III

III

I

23160. 1 FACTORY MUTUAL RESEARCH CORPORATION Page 9

ILLUSTRATION 2SPRAY APPLICATION OFTHERMO-LAG COATING

(3259-1)

~ ~ « ~

$~ P

V,+'

ILLUSTRATION 3CLOSE-UP OF GLASS FIBERBETWEEN COATINGS

(3259-2)

I

I

III

I

I

Page 1.0 FACTORY MUTUAL RESEARCH CORPORATION 23160.1

ILLUSTRATION 4

COLUMN ASSEMBLYBEFORE TEST

(3259-3)

I

I

I

23160. 1 PACTORY MUTUAL RESEARCH CORPORAllON Page ll

FURNACE TEMPERATURESFIRE ENDURANCE TESTJULY 5, 1973TSI~ INC ~

Xllustratioa 5

~ ~

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23160. 1 FACTORY MUTUAL RES jARCH CORPORATION Page 12

COLUMN STEEL TEMPERATURES

FIRE ENDURANCE TESTJULY 5, 1973TSI$ INC ~

Illustration 6

~ ~ ~ ~ ~ ~ ~ oVI

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23160. 1 FACTORY MUTUAL RESEARCH CORPORATION Page 13

ILLUSTRATION 7

COLUM ASSEMBLYAFTER TEST

'

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(2359-4)

ILLUSTRATION 8

COLUMN ASSEMBLYAFTER TESTVIEW TO THE COLUMN WEB

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I

Page 14 FACTORY MUTUAL RESEARCH CORPORATION 23160.1

Test

by.'ire

Technology GroupNational Gypsum CompanyDesign CT-36

Technical Supervision of Construction and Pire Test by:

W. R. PriceEngineerFactory Mutual Engineering Association

Report by:

W. P. ShieldEngineerFactory Mutual Research Corporation

I

I

I

+%a ~ '

DEPART% EMT OF TRANSPORTATlOHFKOEIRAL, RAttRO~ AQ&lHlSTRAT(CW

NAkrlIPe4fOit, 4 C NOOO

pj's 1585

Or. N. Fel&aoTSI Inc.3260 Brannon AvenueSt. Loufs, Hfssourf 63)39

Qoar Hr. Feldman:

In reference to your letter ef Oece+er 10, 1975.'eqvestfny testdata perlonied on TSI-Thermolay 330-I I have asked the 8allfstfc .

llesearch Laboratory. to furnfsh you ef Q the copy Of Report 1lo.459. The results ot tests conducive& on a variety of ne'.erfall

. fn at.'&ftfon to yours are represented fn the report. The data fsfn code. Your materfal fs,coded C-2, and the dfscussfon of theresu)ts of your raterfals itart on pige 46 of the report.

Ifyou have any addftfonal questfons concernfnl the reported AtI,feel free to contact ee.

'fncerely,

Don LcvfneActfny Chfef, RaflVehfc)e Safe> Rcseareh Nvfefoe

I

II

III

I

IIII

I

TABLE OF CONTEiJTS

lSECTION I

Comparison of Insulated Tests With and WithoutTHERMO-LAG (C-2 Coating) 1/8 Inch ThickFire Hose Wa te r Tes t.

SECTION IISimulated Pool Fire Test on THERMO-LAG CoatedPlate 1/8 Inch

SECTION'IISimulated Pool Fire Test on THERMO-LAG CoatedPlate 3/16 Inch

IIII

SECTION IV

Simulated Pohl Fire Test on THERMO-LAG CoatedPlate 1/4 Inch

SECTION V

Full Scale Tank Car Tests

SECTION VX

Bare Tank Car Torch Test

I SECTION VIIThermocougle Layout

II

Full Scale Torch Test - THERMO-LAG Coated Car

SECTION IX

Results of JAN Cycle Testing on 1/5 Model TanksCoated with THERMO-LAG

DEPARTMENT OF -TRANSPORTATIONFEDERAL RAILROAD ADMINISTRATION

WASHlNGTQN, O.C. 20590

JUN 2 y >9yp

Or. Rubin FeldmanPresident, TSI Inc.3260 Brannon AvenueSt..Louis, Missouri . 63239.

Dear Or. Feldman:

As per your telephone request on June 16, 1977, I am enclosing copiesof fire data generated on test plates equipped with your material. Thedata included are:

a) A comparison of insulated tests with and without coating.Also,a 1/8" TSI coated plate subjected to a fire hose.

b) Simulated Pool Fire'est on TSI coated plate - 1/8" inch.

c) Simulated Pool Fire Test on TSI coated plate - 3/6" inch.

d) Simulated Pool Fire Test on TSI coated plate - l/4" inch.

If you have, any questions concerning this data, please feeI free tocontact me.

S ince rely,

on Levi eChic f, Ra i 1 Vehi c le Sa fetyResearch Division

Enclosure

SECTION I

COMPARISON OF .INSULATED TESTS

WITH AND WITHOUT

THERMO-LAG (C-2 COATING)

1/8 INCH THICK

FIRE HOSE WATER TEST

&MPWOW I%4&TE%Wl&A'.i19%THPPl

~" C-2 COATING j./8: INCH THICK FIRE HOSE WATER TEST

t'NINSULATED',t'ARE PLATE

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SECTION VIII

FULL SCALE"TORCH TEST

THERMO-LAG COATED CAR

I

TORCH TEST ON TSl-COBTED CRR- 2K BUG t97EWHY YEQTKBL RN tr THNNCOOPLES

3S'S39

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TORCH TEST ON TSt-COBTED CHR: 2% RUE t97ESCCNO |tEQTLCK BGH Qf'HEQNQlOH.ES

TORCH TEST ON TSt-COBTEO CRR: K'UE l976THlRO VEQTKH. RR fF THNNGNKES

TORCH TE'ST ON TSl-COHTED CBR: K'UE )976FllURTH lENTLGL RN QF THERNCGUKKS

l7 Q3

Plz'88 0Plzz

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TORCH TEST ON TSl-CORTED CRR- 2K RUE t9765!XIH TERTKBL KR fF THERtlQGmpLES

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TORCH TE5T ON T5l-CORTEP CRR: 2K RUE l9765CG1N RGQ GF'tKB5QCOUFLES

TORCH TE5T DN TSl-CORTED CRR- 25 RUE IB7ENlDDK RN OF'KRNCDUFLCS

TORCH'EST GN TSt-COBTEI> CHR- 2K RLIE 1976RlUBTH 80Q OP THERNNDUKE5

'

l HHH

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'"1. 4r4'"7.:341~U ~ V JU

SECTION IX

RESULTS OF JAN CYCLE TESTING

ON 1/5 MODEL'ANKS

COATED WITH THERMO-LAG

~ ~ 1 ~

~ ~ 1I ~ g g

~ t ~ glq g ~

0 EPA RTMENT OF TRAN SPORTATIONFEDERAL RAILROAD ADMINI5TRATION

WASHINGTON, D.C. 20590

FE8 9 1971

Dr. Rubin Feldman.President, TSI-Inc.3260 Brannon AvenueSt. Louis, Msssourr

Dear Dr. Feldman:

Subject: Results of JAN Cycle Testing on 1/5 Model Tanks

-This is in response to your inquiry on the status of the environmentaltests conducted on three (3}', one-fifth,.scale tanks, equipped withTSI thermo-lag material.

The test tanks were positioned in the conditioning-oven on December15, 1976, and were withdra'wn on January 12; 1977. The tanks werecycled in accordance with the temperature profile indicated in Enclosure1. The JAN cycle temperatures were modified to include temperatures of-40'F to +140'F, since these represent the normal temperature extremesencountered in land transportation. The unmodified JAN cycle is normallyrun between -65'F to +165'F, for fourteen days (14}, (Figure 2}.

However, two modified JAN cycle tests were run instead of one (28 daysinstead of 14 days}. Attachment 2, is the test report which I received'fro'm the Army Ballistics Research Laboratory. Aside. from a slightsoftening of the coating at elevated temperatures, no deleterious effects

- of the environmental treatment was found. I will forward pictures of thetest tanks to you when they become available to me.

Please let me know if you have any additional, questions concerning this. test.

Sincerely,

. I

'Don LevineChief, Rail Vehicle Safety

Research Division

DEPARTt1FNT OF THE ARMYht> Baicy/m«~,/; 01U. s.'R4IY .nAL'STic REscARcH LAoof2ATQRIEs 278ABEROEEN PROVING,CROUNO, MARYLAND 21005

DRXBR-9i~af 19 January 1977

rDepirtmcnt of TransportationFederal Railroad AdministrationATTN: her. Don Levine

Program h1anagerSecond and V Streets, SW

Washington, D.C. 20590

Dear hir. Levine:

Three .1/5 scale tanks which had been spray coated with 200 milsof Thermolag .and left to weather for two years at the TransportationTest Center, Pueblo, Colorado were shipped to the Aberdeen Provinp-Ground for JAN Cycle t'esting.

Since the tanks had never had a top coat applied, a thin topcoat was brushed on and allowed to dry. prior to testing. JANcycle testing began at 0800 15 December 1976.

Thd JAN Environmental.Cycle was conducted in the Mortar andRecoilless Rifle Con'ditioning Unit, SP 23. The unit has a testchamber 7 feet wide, 13 foot long and 8 feet, 6 inches high inwhich temperature and humidity can be simulated. Temperature andhumidity were controlled and recorded by two Ilone~iell htodelD8212318001 instr«ments. Air velocity was sufficient to maintaina temperature gradient of + 2 F throughout the chamber aftertemperature stability was achieved.

The SP 23 condi.tionin'g chamber is designed without a floor so thatit can be positioned over an emplaced weapon for conditioning.For this test the floor area was covered with 1 inch thick plywood .

which was covered with 4,inch thick fiberglass insulation and a

DR%BR-IA4

polycthylcnc plastic moisture barrier. After the floor-wasprcparcd, two 6 hy 6 inch wooden beams werc placed acoss thcwidth of thc'chamhcr and the three spray coated tanks spottedon thc beams.

'h

The test was conducted in accordance with Test 105 of MIL-STD-331 (JANTemperature and llumidity Cycle) Figurc 1. The cvclc was modifiedso that thc temperature extrcmcs were -40 F (-65 F specified) ando 0

140 F (160 F specified) as shown in Figuic 2. After 28 days onJanuary 12, 1977 the testing was terminated and thc tanks removedfrom thc chamber. 'i'hc sprayed coatings 'remained intact on allthrcc of thc tanks and showed little change in appearance asverified by the attached photographs. Checks made during thetesting indicated that some softening of thc top coat occurredat thc high tcnperatur« (140 F) high humidity (95'.) cnd of thecycle. Attention should be called to the fact that. this is anunusually severe test and that these conditions would never beexperienced in ordinary operating conditions. The Army usesthis type of test only on fuzes and munitions where a problemof chemical stability and resultant safety are of concern.

Sincerely yours,

2 Inclsas

E. 0. BAICYProgram ManagerTank Car Project'

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FIGljRI: .'~

PRELIMINARY ACCIDENT REPORT

TANK CAR DERAILMENT

JOAQUIN, TEXAS,

SEPTEMBER 8, 1979

PREPARED BY:

TSI, INC.

OCTOBER, 1979

TSI, INC. ~ 3260 BRANNON AVE. ~ ST. LOUIS, hhO. 63139 ~ (314) 352-8422 ~ Telex:.44-2384

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ABSTRACT

On September 8, 1979, two TSI THERMO«LAG 330 coated(fire and impact protected) tank cars, loaded withbutadiene, were involved in a major derailment andsubsequent fire near Joaquin, Texas.

Twenty-six I (26) tank cars reportedly burned and/orexploded. The two tank cars which were fire andimpact protected with THERMO-LAG 330 Subliming CoatingSystem performed as expected - protecting the tankcar and its lading from the firing inferno. Moredetails and photographs as obtained from the "on thescene" reporters follow.

The thickness of the THERMO«LAG 330 Fire ResistiveCoating applied to the two tank cars was circa0.165 inches dry. THERMO-LAG was approved for fireresistant enhancement of tank cars by the Departmentof Transportation as a result of an extensive fireprotection, physical, environmental and 'life cycletest program conducted by the Department of Transporta"tion, U. S. Army Ballistics Research Laboratories-Aberdeen Proving Ground, and the American RailroadAssociation. THERMO-LAG 330 Fire Resistive„CoatingSystem is specifically listed in and specified byFederal Regulation HM144 for that use.

The THERMO-LAG thermal protective coatings have enjoyed.an unparalleled success in many aerospace programs onsuch prestigious sytems as the X-15, Polaris, Saturn,etc., since the 1950's, and for commercial applicationssince the 1960's.

ACCIDENT SYNOPSIS

"33 cars of a Southern Pacific Freight. derailed ~

near Joaquin Saturday and burst into SPECTACULARFLAMES, spewing dangerous fumes and hugejcloudsof smoke while TRIGGERING PERIODIC EXPLOSIONS.

"It was a nightmare come true,"'aid one residentof a nearby house who ran through fire to escape.

It took almost 36 hours for the 'fire to "burnitself out" enough for repair crews to move inand even at noon Monday several small columns offire and smoke continued to rise from thewreckage.">

Unofficial and preliminary National Transportation SafetyBoard estimates put the damage to the cars and theircontents at more than 2 million dollars.2

"Explosive and toxic chemicals were in 30 loadedcars involved in the derailment, including suchhazardous materials as butadiene, isobutylene,tetrahydrafuran, hydrofluoric acid, ethylene oxide,vinyl acetate, methanol, ethyl acrylate, rubber,acetaldehyde, propylene glycol (antifreeze),paint and

plastics.'hree

of the wrecked cars were empty.

RAIL OFFICIALS SAID 26 OF THE CARS BURNED, WITHSEVERAL OF THEM EXPLODING'"1

The National Transportation, Safety Board's preliminaryinvestigation results confirm the above-.>

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I

"Concern over a slow leak in the "HF" (hydrofluoricacid) car and possible explosion of a butadiene carwas one of the main delays in reopening the highwayand beginning the cleanup operations.

"If it hadda gone, everything. within a mile of herewoulda been levelled," said a Texas Railroad Commissionsafety official on the scene.

After seveal aerial inspections via helicopter ofthe wreckage, officials finally got up the nerve todon artificial breathing devices and make a groundinspection of the cars on ll a.m. Monday.

They reported back that temperature and pressurewithin the "HF" car and the butadiene car appearedto be okay, MUCH TO EVERYONE'S RELIEF, even thoughsome flames persisted in the wrecked cars aroundthem."1

The butadiene loaded tank car in question was a Shell Car,Number SCMX 3646. It was coated in accord with FederalRegulation HM144 prerequisites with THERMO-LAG 330 SublimingCoating System in September 1978. Initial investigationindicates that it was exposed to simultaneous torching andfire engulfment from several cars around it. As you willnote from Photograph N7, after the derailment the geographiclocation resembles a ravine. ,All the tank cars subject tothe derailment or involved in the derailment were piledinto a tight proximity to one another, literally adj'acentto each other irrespective of their initial order in whichthey were placed on the train. The condition of theTHERMO-LAG protected tank car, as reported in the preliminaryNTSB investigation was "Engulfed by fire - no product loss"

2even though there was a 920,000 damage to the car as aresult of the derailment.

Photographs SPl through N6 show closeup views of theTHERMO-LAG protected car after the derailment. You willnote that with the exception of the replacement of thecoating which had been consumed as per the design, and

the mechanical repairs which will need to be made, noother damage occurred. The tank car was properlyprotected from fire. There was no explosion or otherfailure that would have endangered life or propertyand the lading was essentially left intact.

Photographs N8 through 13 show closeups of thewreckage. Please note that the tank cars in thewreckage, with the exception of the THERMO-LAG protectedcar, are beyond repair. Even though the THERMO-LAGprotected tank car was subjected to many impacts, itperformed as anticipated.

More details on this accident will be made availablevery soon. We welcome your inquiries.

TSI, INC.3260 Brannon AvenueSt. Louis, Missouri 63139

Phone: 314 352-8422

REFERENCES

References used in the preparation of this PreliminaryAccident Report are as follows:

THE EAST TEXAS LIGHT, Shelby County, TexasP 0 Box 1289Center, Texas 75935(173) 598-3377

Wednesday, September 12, 1979Volume 56, Number 64

TRAIN WRECK SPEWS DANGER»

By Wain Miller

National Transportation Safety Board Hearing

"NTSB Meeting - Joaquin, Texas DerailmentSeptember 8, 1979

Held at Houston, Texas SP BuildingOctober 3-4"

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PHOTOGRAPH 813

SCENE OF THE ACCIDENTTANK CAR DERAILMENT AND FIRE

JOAQUIN, TEXASSEPTEMBER 8, 1979

PHOTOGRAPH 812

SCENE OF THE ACCIDENTTANK CAR DERAILMENT AND FIRE

JOAQUIN, TEXASSEPTEMBER 8, 1979

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t,'HOTOGRAPH 811

SCENE OF THE ACCIDENTTANK CAR DERAILMENT AND FIRE

JOAQUIN, TEXASSEPTEMBER 8, 1979

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SCENE OF THE ACCIDENTTA%C CAR DERAILMENT AND FIRE

JOAQUIN, TEXASSEPTEMBER 8, 1979

I

PHOTOGRAPH 89

SCENE OF THE ACCIDENTTANK CAR DERAILMENT AND FIRE

JOAQUIN, TEXAS

SEPTEMBER 8, 1979

PHOTOGRAPH 88

SCENE OF THE ACCIDENTTANK CAR DERAILMENT AND FIRE

JOAQUIN, TEXASSEPTEMBER 8, 1979

PHOTOGRAPH 717

AERIAL VIEW » WRECKAGETANK CAR DERAILMENT

JOAQUIN, TEXASSEPTEMBER 8, l979

PHOTOGRAPH 86

THERMO-LAG PROTECTED TANK CAR

AFTER 36 HOUR EXPOSURE TO FIRE

JOAQUIN» TEXASSEPTEMBER 8, 1979

PHOTOGRAPH g5

THERMO-LAG PROTECTED TANK CARAFTER 36 HOUR EXPOSURE TO FIRE

JOAQUIN, TEXASSEPTEMBER 8, 1979

1

PHOTOGRAPH 84

THEm-LAG PROTECTED TANK CARAFTER 36 HOUR EXPOSURE TO FIRE

JOAQUIN, TEXASSEPTEMBER 8, 1979

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THERMO-LAG PROTECTED TANKAFTER 36 HOUR EXPOSURE TO

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SEPTEMBER 8 1979

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PHOTOGRAPH 82

THERMO-LAG PROTECTED TANK CARAFTER 36 HOUR EXPOSURE TO FIRE

JOAQUIN, TEXAS

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THERMO"LAG PROTECTED TANK CARa AFTER 36 HOUR EXPOSURE TO FIRE

OAQUIN, TEXASSEPTEMBER 8, l979

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TSI TECHNICAL NOTE 80181

THERMO-LAG 330-1

SUBLIMING COATING ENVELOPE SYSTEM

APPLICATION PROCEDURES

8/81

REVISION I

TSI TECHNICAL NOTE 80181

REVISION I

8/81

PREPARED BY:Wilbur 'PaddockManager of Production

REVIEWED BY:R. A. manMan r, Quality Assurance

APPROVED BY:R. FeldmanPresident

TABLE,OF CONTENTS

SECTION TITLE PAGE NO.

1.0 INTRODUCTION

2.0

3.0

UNPRE-APPLICATION

=PRACTICES

FABRICATION OF STRESS SKIN ENVELOPE

4.0

5.0

6.0

COATING APPLICATION TECHNIQUES

TOPCOAT- APPLICATION

POST APPLICATION PRACTICES

19

22

22

7.0 EQUIPMENT SUGGESTIONS 23

APPENDIX A SCHEMATIC OF SUGGESTED PENETRATINGMEASURING DEVICES 24

APPENDIX B SUGGESTED COMPLEMENT OF REQUIRED SPRAYEQUIPMENT FOR THERMO-LAG 330-1 SUBLIMINGCOATING APPLICATION 25

APPENDIX C APPLICATION PROCEDURES — STRUCTURALSTEEL ENTITIES 27

APPENDIX D

APPENDIX E

TYPICAL APPLICATION DETAILS

FIREPROOF COATING THICKNESSESREQUIRED FOR VARIOUS STRUCTURALSTEEL MEMBERS

I'slLIST OF FIGURES

FIGURENUMBER TITLE

PAGENO.

1.0.3

1.0.4a

1.0.4b

1.0.5a

1.0.5b

1.0.6a

1.0.6b

1.0. 7

THERMO-LAG Stress Skin Type 330-69Typical Layout for Cable Tray Sections

THERMO-LAG Stress Skin Type 330-69Installation Schematic Prior toTHERMO-LAG 330-1 Subliming CoatingApplication

Cross Sectional View of THERMO-LAG 330-1Subliming Coating Envelope System Appliedto a Typical Cable Tray

THERMO-LAG Stress Skin Type 330-69Installation Schematic Prior- toTHERMO-LAG 330-1 Subliming CoatingApplication

Installation Schematics For AttachingAdditional Sections of THERMO-LAG

Stress Skin Type 330-69 to PreviouslyInstalled THERMO-LAG Stress SkinType 330-69

Cross Sectional View of THERMO-LAG 330-1Subliming Coating Envelope System Appliedto Cable Drops

Cross Sectional View of THERMO-LAG 330-1Subliming Coating Envelope System Appliedto Cable Drops

Cross Sectional View of THERMO-LAG 330-1Subliming Coating-Envelope Syst'm Appliedto Conduit and Cable Drop

Cross Sectional Vi'ew of THERMO-LAG 330-1Subliming Coating Envelope System Appliedto Cable Tray and Cable Drop

Cross Sectional View of THERMO-LAG 330-1Subliming Coating Envelope System Appliedto a Junction Box Assembly

9a

9b

10a

12a

13a

13b '

TSI TECHNICAL NOTE 80181

THERMO-LAG 330-1

SUBLIMING COATING ENVELOPE SYSTEM

APPLICATION PROCEDURES

1.0 INTRODUCTION

This procedure, sets forth the sequential steps involved in applyingTHERMO-LAG 330-1 Subliming Coating Envelope System to cable trays,cable drops, conduit, )unction box assemblies, and structural steel.

The „THERMO-LAG 330-1 Subliming Envelope System consists of THERMO-LAG

Stress Skin Type 330-69, THERMO-LAG 330-1 Subliming Coating, FiberglassArmoring, and where required., THERMO-LAG 330-70 Conformable CeramicBlanket and. THERMO-LAG 350 Two Part Spill Resistant Topcoat.

2.0 PRE-APPLICATION PRACTICES

2.1 alifications of Contractor

The application shall be performed by a qualified'ontractor who hashad prior training in applying the material and who has the equipmentrequired to perform the application.

2.2 Safet Precautions

The contractor shall follow standar'd industrial safety, practicesestablished for the handling of chemical coatings and shall conformto applicable OSHA and owner safety rules in all respects.

2.3 ~Deliver

The coating materials shall be delivered to the gob site in original,.unopened containers which show, the'product name, batch number, color,name of the manufacturer, the expiration date, and where applicable,an Underwriters'aboratories label.

2.4 ~Stora e

The coating materials shall be stored off the ground when'ot inuse in an area provided for that purpose. The materials in storageshall be protected against freezing and from temperatures above 100'F.

2.5 Tem erature and Preci itation

The coating 'materials shall be applied only to dry surfaces. Thetemperature of the coating material and surfaces to be coated shallbe above 40'F during the material application and curing periods.The contractor shall furnish and install any protective covers "

required to protect the newly applied coating from rainfall or hardfieeze during its initial curing period.

2.6 Protection of Ad acent Surfac'es

The contractor shall mask off or otherwise protect all adjacent areasand in place equipment from receiving any material overspray duringthe coating application. Any spilled material and overspray shall beremoved promptly using water, wet rags or sponges before the materialhas dried.

3.0 FABRICATION OF STRESS SKIN ENVELOPE

3.1 Cable Tra s (Fi ures 1.0.1, 1.0.2, 6 1.0.3)

3.1.1 Cut a piece of material large enough to form the bottom section froma roll of Stress Skin. The width of the bottom section sha'll be equalto the sum of the base (W) and both sides (H) of the cable tray plus34 inches, as shown in Figure 1.0.1 . The length of the bottom pieceof material shall not exceed 10 feet since longer sections areunwieldy and are difficult to install.

3.1.2 Cut a square 14 inch piece from each corner of the bottom section ofthe Stress Skin.

3.1.3 Form a "U" shaped section by making two 90'ends along the dotted lineswhich are located at each end of the W + 4" dimension line shown inFigure 1.0.1.

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3.1.4 Form a 14" flange on each side of the'ottom section by making a 90'bend along the dotted lines as shown in Pigure 1.'O.l.

3.1.5 Cut a piece of material large enough to form the top section from aroll of Stress Skin. The width of the top section shall be equal tothe'base (W) of the cable plus 24".

3.1.6 Porm a 14" flange at each end of the top section by making 90'endsalong the dotted lines shown in Figure 1.0.1.

3.1.7 Drill holes for fastening the bottom and top sections together asrequired in the flanges of both sections as shown in Figure 1.0.2.

Mount the bottom and top sections of Stress Skin on the cable trayand fasten the two sections, together at a maximum of six inch intervalsusing mechanical fasteners, staples or 18 ga. galvanized tie wire.

3.1.9 Attach additional 'bottom and top sections of Stress Skin to a previouslyinstalled section by fastening them together at the 'end flanges usingmechanical fasteners, staples or 18 ga. galvanized tie wire.

3.1.10 Coat the bottom and top sections of Stress Skin with THERMO-LAG 330-1Subliming Coating as shown in Figure 1.0.3. ,The coating shall beapplied with Fiberglass Armoring in accordance with the instructionsgiven in Section 4.0 of this procedure.

OR WHEN COATING'PRIOR TO MOUNTING

3.1.11 Coat the bottom and top sections of Stress Skin with THERMO-LAG 330-1Subliming Coating prior'to mounting on the cable tray. The coatingshall be applied with Fiberglass Armoiing in accordance with instruc-tions given in Section 4.0 of this'procedure.

3.1.12 Drillholes for fastening the bottom and top sections together as .

required in the flanges of both sections as shown in Figure 1.0.2.

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FIGURE 1.0.2

THERMO-LAG STRESS SKIN TYPE 330-69

INSTALLATION SCHEMATIC PRIOR TO

THERMO-LAG 330-1 SUBLIMING COATING APPLICATION

TOP SECTION

HOLES FORMOUNTING

S1IFFENERS

BOTTOM SECTION PLANGES

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FIGURE 1.0.3

CROSS SECTIONAL VIEW OF

THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM

APPLIED TO A TYPICAL CABLE TRAY

THERMO-LAG330-1SUBLIMINGCOATING

CABLETRAYSHELL

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FIBERGLASSARMORING

THERMO-LAG STRESS SKINTYPE 330-69

. CABLES

3.1.13 Mount the bottom and top sections of the precoated Stress Skin on thecable tray and fasten the two sections together at a maximum of sixinch intervals using mechanical fasteners, staples or 18 ga. galvanizedtie wire.

3.1.14 .'Attach additional precoated bottom and top sections of Stress Skin to apreviously installed section by fastening them together at the endflanges using mechanical fasteners, staples or 18 ga. galvanized tie wire.

3.1.15 Apply a coating of THERMO-LAG 330-1 Subliming Coating in the specifiedwet film'hickness to the edges and joints of the precoated sections ofStress Skin using a trowel or stiff bristle brush to fillin any gapsor fastening holes.

3.2 Conduit (Fi re 1.0.4

3.2.1 Cut two pieces of Stress Skin large enough to form a top and a bottomsection for the conduit. The width of each piece shall be equal to4", of the circumference of the conduit plus 1". The length of the'piece of Stress Skin shall not exceed 10 feet since longer sectionsare unwieldy and more difficult to install.

3.2.2 Form a semi-circular section with edge flanges from each of the twopieces by making two 90'ends at a distance of 1/2 inches from eachedge of the width dimensions as shown in Figure 1.0.4a.

For sharp radius bends, the procedure delineated in Section 3.0 forthe fabrication of Stress Skin Envelope utilizing, a design as shownin Figure 1.0.2 shall apply for conduit when sharp radius bendsmust be coated.

3.2.3 Form a 4" flange on the length edges of each of the two pieces, whererequired, by making 90'ends.

3.2.4 Drill holes for fastening the bottom and top sections together at amaximum of six inch intervals in the flanges of both sections whenrequired.

3.2.5 Mount the bottom and top sections of Stress Skin on the conduit andfasten the two sections together at a maximum of six inch intervalsusing mechanical fasteners, staples or 18 ga. galvanized tie wire.

3.2.6 Attach additional bottom and top sections of Stress Skin to apreviously installe'd bottom snd top sections as shown in Figure1.0.4b.

a) Overlapping the'bottom and top sections by a maximum ofor

b) Pastening them together at the end flanges using mechanicalfasteners,'taples or 18. ga. galvanized tie wire.

3.2.7 Coat the bottom and top sections of Stress Skin with THERMO-LAG 330-1Subliming Coating The coating shall be applied with PiberglassArmoring in accordance with instructions given in Section 4.0 ofthis procedure.

OR WHEN COATING PRIOR TO H)UNTING

3.2.8 Coat the bottom and top sections of Stress Skin with THERMO-LAG 330-1Subliming Coating prior to mounting on the conduit. The coatingshall be applied with Piberglass Armoring in accordance with instruc-tions given in Section 4.0 of this procedure.

3.2.9 Drill holes for. fastening the bottom and top sections together asrequired in the .flanges of both sections.

3.2.10 Mount the bottom and tops secti'ons of the precoated Stress Skin onthe conduit and fasten the two sections together at a maximum ofsix inch intervals using mechanical fasteners, staples or 18 ga.galvanized tie wire.

3.2.11 Attach additional precoated bottom and top sections of Stress Skinto a previously installed section by fastening them together at theend flanges using mechanical fasteners, staples or 18 ga. galvanizedtie wire as shown in Pigure 1.0.4b.

3.2.12 Apply a coating of 'GKBHO-LAG 330-1 Subltudng Coating in the specifiedwet film thickness to the edges and points of the precoated sectionsof Stress Skin using a .trowel or stiff bristle brush to fillin .anygapa or fastening holes.

I

FIGURE 1.0.4a

THERMO-LAG STRESS SKIN TYPE 330-69

INSTALLATION SCHEMATIC PRIOR TO

THERMO-LAG 330-1 SUBLIMING COATING APPLICATION .

THERMO-LAG StressSkin Type 330-69

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Conduit

9a

FIGURE 1.0.4b

INSTALLATION SCHEMATICS FOR ATTACHING ADDITIONAL SECTIONS OF

THERMO-LAG STRESS SKIN TIVE 330-69 TO PREVIOUSLY INSTALLED

THERMO-LAG STRESS SKIN TYPE 330&9

THERMO-LAG STRESS SKIN'

END FLANGES

END FLANGES

THERMO-LAG STRESS SKIN

CONDUIT

THERMO-LAG STRESS SKIN

THERMO-LAG STRESS SKIN

2" M1nimum Overlap

CONDUIT

9b

'I

3.3 Cable.Dro s (Fi ure 1.0.5 )

3.3.1 Cut a piece of Stress Skin large enough to wrap around the circum-,ference of a single or multiple number of cable drops. The widthof the piece should be equal to the circumference of the single orgroup of cable drops plus an additional 3/4" minimum to provide forthe overlap. The length of the piece of material shall not exceed10 feet since longer sections are unwieldy and more difficut to handle.

3.3.2 Wrap the piece of Stress Skin around the single or group of cable dropsand secure at a maximum of six inch intervals with 18 -ga. galvanizedtie wire. Attach additional pieces of Stress Skin to a previouslywrapped piece by overlapping by a minimum of six inches and securewith 18 ga. galvanized tie wire.

3.3.3 Cut a piece of THERMO-LAG 330-, 70 Conformable Ceramic Blanket largeenough to wrap around the circumference of the installed Stress Skin.The width of the'piece should be equal to the circumference of theinstalled Stress Skin plus Q" minimum to provide for a tight abutmentof the edges. The length of the piece of material shall not exceed10 feet in order to minimize the handling problems during installation.

3.3.4 Wrap the piece o'f Conformable Ceramic Blanket around the installedpiece of Stress Skin and secure at a maximum of six inch intervalswith 18 ga. galvanized tie wire. Attach additional pieces as requiredof the Conformable Ceramic Blanket to a previously installed piece bytightly abutting the pieces together. Care should be exercised toensure that the wrapping of the Conformable Ceramic Blanket iscontinuous with no gaps or holes in the material surfaces.

3.3.5 Cut two pieces of Stress Skin large enough to form a top and abottom section. The width of each piece shall be equal to one halfof the circumference of the installed Conformable Ceramic Blanketplus 2Q" minimum. The length of the piece of material shall not exceed10 feet since longer sections are unwieldy and more difficult to handle.

3.3.6 Form a semi-circular section with edge flanges from each of the toppieces by making two 90'ends at a distance of lg" minimum from eachedge of the width dimension.

10

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FIGURE I.O,5~

CROSS SECTIONAL VIEW OF

THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM

APPLIED TO CABLE DROPS

THERMO-LAG 330-1FIBERGLASS 'ARMORING

THERMO-LAG 330-1

TEERNO-LAG STRESS SKIN-r

CONFORMABLE CERAMIC BLANKET

THERMO"LAG STRESS SKIN

TIE WIRE

l ~WE

r

r

FASTENER

TIE WIRE

3.3.7 Form a 14" flange on the length edges of each of the two pieces,when required, by making 90'ends.

3.3.8 Cut holes for fastening the bottom and top sections together at amaximum of six inch intervals in the flanges of both sections.

3.3.9 Mount the bottom and top sections. of Stress Skin on the ConformableCeramic Blanket and fasten the two sections together at a maximum ofsix inch intervals using mechanical fasteners, stapes or 18 ga.galvanized tie wire.

3.3.10 Attach additional bottom and top sections of Stress Skin to apreviously installed bottom and top section by fastening themtogether at the end flanges using mechanical fasteners, staples or18 ga. galvanized tie wire.

3.3.11 Coat the bottom and top sections of Stress Skin with 'QiERMO-LAG 330-1Subliming Coating as shown in Figure 1.0.5a. The coating shall beapplied with Fiberglass Armoring in accordance with the instructionsgiven in Section 4.0 of this procedure.

.3.3.12 Cable Drops (Fi ure 1.0.5b)

3.3.12.1 Cut a piece of Stress Skin large enough to wrap around the circum-ference of a single or multiple number of cables. The width ofthe piece should be equal to the circumference of the single orgroup of cable drops plus an additional 3/4" minimum to providefor the overlap. The length of the piece shall not exceed10 feet since longer sections are unwieldy and more difficult tohandle.

3.3.12.2 Wrap the piece of Stress Skin around the single or group of cabledrops and secure at a maximum of six inch intervals with 18 ga.galvanized tie wire. Attach additional pieces of Stress Skinto a previously wrapped piece by overlapping by a minimum ofsix inches and secure with 18 ga. galvanized tie wire.

3.3.12.3 Coat the section of Stress Skin with THERMO-LAG 330-1Subliming Coating as shown in Figure 1.0.5b. The coatingshall be applied with Fiberglass Armoring in accordancewith instructions given in Section 4.0 of,this procedure.

3.3.12.4 Cut a piece of 'THERMO-LAG 330-70 Conformable Ceramic Blanketlarge enough to wrap around the circumference of the installedStress Skin. The width of the piece should be equal to thecircumference of the installed Stress Skin plus g" minimumto provide for a tight abutment of the edges. The length ofthe piece of material shall not exce'ed 10 feet in order tominimize the handling problems during installation.

3.3.12.5 ~ Nrap the piece of Conformable Ceramic Blanket. around theinstalled piece of Stress Skin and secure at a maximum ofsix inch intervals with 18 ga. galvanized tie wire. Attachadditional pieces as required of the Conformable CeramicBlanket to a previously'nstalled piece by tightly abuttingthe pieces together. Care should be exercised to ensure thatthe wrapping of the Conformable Ceramic Blanket is continuouswith no gaps or holes in the material surfaces.

3.3.12.6 Cut two pieces of Stress Skin large enough to form a'topand a bottom section. The width of each piece shall beequal to one half of the circumference of the installedConformable Ceramic Blanket plus 2g" minimum. The lengthof the piece of material shall not exceed 10 feet sincelonger sections are unwieldy and more difficult to handle.

3.3.12.7 Form a semi-circular section with edge flanges from eachof the top pieces by making two 90'ends at a distance oflg" minimum from each edge of the width dimension.

12

FIGURE 1.0.5b

CROSS SECTIONAL VIEW OF

THERMO-LAG 330»1 SUBLIMING COATING ENVELOPE SYSTEM

APPLIED TO CABLE DROPS

THERMO-LAG 330-1FIBERGLASS ARMORING

THERMO.'-LAG 330-1

THERMO-LAG STRESS SKIN

CONFORMABLE CERAMIC BLANKETTHERMO-LAG 330-1THERMO-LAG STRESS SKIN

l< S

rr i~J rC

FASTENER

TIE WIRE TIE WIRE

12a

I

I

3.3.12.8 Form a 14" flange on the length edges of each of the two pieces,when required, by making 90'ends.

3 3.12-9 'ut holes for fastening the bottom and top sections together. at amaximum of'ix inch intervals in the flanges of both sections.

3 '.12 10 'Mount the bottom and top sections of,'Stress Skin on the Conformable,Ceramic Blanket and fasten the two sections together at a maximum ofsix inch intervals using mechanical fasteners, stapes or 18 ga.galvanized tie wire.

3.3.12.11 Attach additional bottom and top sections of Stress Skin to apreviously installed bottom and top section by fastening themtogether at the end flanges using mechanical fasteners, staples or18 ga. galvanized tie wire.

3.3.12.12 Coat the bottom and top sections of Stress Skin with THERMO-LAG 330-1Subliming Coating as shown in Figure 1.0.5b. The coating shall beapplied with Fiberglass Armoring in accordance with the instructionsgiven in Section 4.0 of this procedure.

3.4 Conduit and Cable Dro Junction (Fi ure 1.0.6)

3.4.1 Apply the THERMO-LAG 330-1 Subliming Coating Envelope System to theconduit and the single or multiple cable drops following theinstructions'given in Section 3.2 or 3.3 of this procedure.

3.4.2 Cut a piece of Stress Skin of sufficient size to wrap around thecircumference of the conduit. The width of the piece should beequal to the outside circumference of the conduit plus an additional3/4 inch to provide for an overlap. The length of the piece shall be12 inches minimum.

3.4.3 Wrap the piece, of Stress Skin around the outside circumference of theconduit in such a manner that it. covers six inches of the conduit.Secure the piece of .'Stress Skin to the conduit with'two 18 ga. gal-vanized tie wires mounted approximately 5 inches apart.

13

FIGURE 1.0.6a

CROSS SECTIONAL VIEW OF

THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM

APPLIED TO CONDUIT .AND CABLE DROP

CONDUIT

THERMO-LAG 330-1

THERMO-LAG STRESS SKINFIBERGLASS ARMORING

FIBERGLASS ARMORINGTHERMO-LAG'STRESS~SKI

r

5rBEVELED EDGE OF .

CTHERMO-LAG 330-1AND FIBERGLASSARMORING

CABLE DROP~

THERMO-LAG 330-1

THERMO-LAG STRESS SKIN

13a

I

3.4.4 Cut a required number of small pieces of THERMO-LAG 330-70Conformable Ceramic Blanket from a roll of this material.

3.4.5 Insert the small pieces of Conformable Ceramic Blanket inside theopen end of the installed piece of Stress Skin and around and betweenthe cable drops in such a manner that the open end is relativelysealed. Then secure the. piece of Stress Skin to the cable drops with18 ga. galvanized tie wires.

3.4.6 Coat the installed piece of Stress Skin with THERMO-LAG 330-1Subliming Coating as shown in Figure 1.0.6. The coating shallbe applied with Fiberglass Armoring in accordance with the instruc-tions given in Section 4.0 of this procedure.

3.5 Cable Tra and Cable.Dro Junction at 0 en End of Cable Tra

3.5.1 Apply the THERMO-'LAG 330-1 Subliming Coating Envelope System to thecable tray at the single or mu1tiple cable drops following theinstructions given in Sections 3-1 and.3.3 'of this procedure.

'.5.

2 Cut a piece of Stress Skin of sufficient size to wrap around theoutside parameters of the cable tray. The width of the pieceshould be equal to the outside parameter of the cable tray plusan additional 3/4" 'to provide for .an overlap. The length of thepiece shall be 24 inches minimum.

3.5.3 Wrap the piece of Stress Skin around the parameter of the cable trayin such a manner that it covers six inches of, the conduit. Secure thepiece of Stress Skin to the conduit with two 18 ga. galvanized tiewires mounted approximately 5 inches apart.

3.5.4 Cut a required number of small pieces of the THERMO-LAG 330-70Conformable Ceramic Blanket from a roll of this material.

3.5.5 Cut slots approximately 12 inches in length at each corner of theopen end of the piece of Stress Skin.

14

FIGURE 1.0.6b

CROSS SECTIONAL VIEW OF

THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM

APPLIED TO CABLE TRAY AND CABLE DROP

GABLE TRAY

BEVELED EDGE OF THERMO-LAG 330-1 AND FIBERGLASS ARMORING

THERMO-LAG 330-1

~MAO-LAC STRESS INFIBERGLASS ARMCRBiG

FIBERGLASS ARggRIN~GIRRRMOLISG S-IRRSS~SKI

r

SABIR DROP~THERMO-LAG 330-)

THERMO-LAG STRESS SKIÃ

3.5.6 Insert the small pieces of Conformable Ceramic Blanket inside theinstalled piece of Stress Skin and around and between the cable dropsin such a manner that when the slit open end of the piece of StressSkin is tightened around the cable drops, the open end is effectivelysealed. Then secure the piece of Stress Skin to the cable dropswith 18 ga. galvanized tie wires.

3.5.7 Coat the installed piece of Stress Skin with THERMO-LAG 330-1Subliming Coating in the required thickness. The coating shall beapplied with Fiberglass Armoring in accordance with the instructionsgiven in Section 4.0 of this procedure.

3.6 Cable Tra and Cable Dro Junction at To or Bottom of Cable Tra

3.6.1 Apply the THERMO-LAG 330-1 Subliming Coating Envelope System to thecable tray and the single or 'multiple cable drops following theinstructions given in Section 3.1 and 3.3.

3.6.2 Cut a piece of Stress Skin of sufficient size to form a truncatedcone shape which has one end that is equal to the circumferenceof the cable drops plus 3/4 inch to provide for overlaps. Theother end should be approximately four times the circumference ofthe cable drops plus 3/4 inch to provide. for overlaps. The lengthof the piece should be 6 inches minimum.

3.6.3 Form a 1" flange at the large end of the piece of Stress Skin bymaking a 90'end along a line which is*1" up and parallel to thelarge end. Drill holes for fastening the flange to the cable trayas required in the flange.

3.6.4 Cut a required number of small pieces of THERMO-LAG 330-70 ConformableCeramic Blanket from a roll of this material.

3.6.5 Form a cone out of the piece of Stress Skin taking care to overlapthe sides by 3/4 inch.

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3.6.6 Insert the small pieces of Conformable Ceramic Blanket inside .thesmall end of the cone in such a manner that the small end is sealedwhen it is wrapped around the cable drops. Then secure the smallend of the piece of Stress Skin to the cable drops with 18 ga.galvanized tie wires.

3.6.7 Secure the flanged end of the piece of Stress Skin to the cabletray using mechanical fasteners, staples or 18 ga. galvanizedtie wires.

3.6.8 Coat the install'ed piece of Stress Skin with THERMO-LAG 330-1Subliming Coating. The coating shall be applied with FiberglassArmoring in accordance with the instructions given in Section 4.0of this procedure.

3.7 Cable Tra or Conduit Junction With Pire Wall

3. 7.1 Attach the Stress Skin Envelope of the cable tray or conduit ateach junction with a fire wall by fastening the butt flange ofthe Stress Skin to the fire wall using mechanical fasteners.

3.7.2 Apply the THERMO-LAG 330-1 Subliming Coating to the butt flanges,overlapping the flange joints with the coating by a minimum of3 inches. The coating shall be applied with Fiberglass Armoringin accordance with the instructions given in Section 4.0 of thisprocedure.

3.8 Junction Box Assembl (Pi ure 1.0.7

3.8.1 Cut two pieces of Stress Skin large enough to form the top and bottomsections of the main assembly section of, the junction box assemblyas shown in Figure 1.0.7. The width of each piece of material shallbe equal to the width of the junction box plus 5 inches and thelength of each piece shall be equal to the depth of the junction boxplus 3 inches. The additional 5 inches provides for 14" flanges and14" clearance from the side. edges of the junction box. The

"additional 3 inches provides for 14" flanges and lg" clearancealong the sides of the junction box.

16

FIGURE 1.0.7

CROSS SECTIONAL VIEW OF

THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM

APPLIED TO A JUNCTION BOX ASSEMBLY

THERMO-LAG330-1

SUBLIMINGCOATING

D

+i"

CONDUIT COVERED WITHTHERMO-LAG STRESS SKIN,THERMO-LAG 330-1 ANDFIBERGLASS ARMORING

THERMO-LAG 330-1AND

FIBERGLASSARMORING

THERMO-LAG 330-1APPLIED TO

THERMO-LAG STRESS SKIN

MAIN ASSEMBLYSECTION

FRONT PLATESECTION

FASTENERS

re~ t

:0THERMO-LAG

'TRESS

SKIN

17

3.8.2 Cut any required holes for cable drops in the top and bottom sections.

3.8.3 Form a 1V'lange on each of the four sides-of the top and bottomsection of Stress Skin by making the required number of 90'ends.

3.8.4 .Drill holes for fastening the top and bottom sections at a maximum of6 inch intervals in the flanges as shown in Figure 1.0.7.

3.8.5 Cut two pieces'f Stress Skin large enough to form the two sidesections of the main assembly section. The width of each piece ofStress Skin shall be equal to the height of the junction 'box plus5 inches and the length of each piece. shall be equal,to the depth ofthe )unction box 'plus 3 inches. The additional 5 inches provides for14" flanges and 14" clearance from the top and bottom edges of thejunction box. The additional 3 inches provides for 14" flanges andV'learance along the sides of the )unction box.

3.8.6 Drill any required holes for cable drops in the two side sections.

3.8.7 Form a 14" flange on each of the four sides of the two side sectionsof Stress Skin by making the required number of 90'ends.

3.8.8 Drill holes for fastening the two side sections at a.maximum of 6inch intervals in the flanges as shown in Figure 1.0.7.

, 3.8.9 Cut a piece of Stress Skin large enough to form the front platesection. The width of the front plate section shall be equal to thewidth of the top and bottom sections plus 24" required to cover t'eflanges. The length of the front plate section shall be equal to 'theheight of the side sections plus 24" required to cover the flanges.

3.8.10 Drill holes for fastening the front plate section to the main assembly .

section as shown in Figure 1.0.7.

3.8.11 Mount the main assembly section around. the junction box by connectingthe top. and bottom sections to the two side sections and attachingthe main assembly section to the wall on which the )unction box ismounted using mechanical fasteners, staples or 18 ga. galvanizedtie wires.

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3.8.12 Mount the front plate section on the main assembly section usingmechanical fasteners, staples or 18 ga. galvanized tie wire.

3.8.13 Coat the assembled front plate 'and main assembly sections of StressSkin with THERMO-LAG 330-1 Subliming Coating. The coating shall beapplied with Fiberglass Armoring in accordance with the instructionsgiven in Section 4.0 of this procedure.

3.9 , Structural Steel Su orts

3.9.1 See Appendix C of this procedure for application instructions.

4.0 COATING APPLICATION TECHNI UES.

4.1 S ra A lication

4.1.1 Apply the THERMO-LAG 330-1 Subliming Coating over a properly preparedsurface. Make sure that the surface to be coated is clean, dry, above40'F and free from scale, rust or'other contaminants.

4.3..2 'pply the material in as many passes as required to provide the, requiredfilm build of coating thickness, taking care to avoid slumping orsagging of the coating. Normally, a required 0.500 inch dry coatingthickness is accomplished by applying three wet coats of 0.225 inches.However, the thickness which can be safely applied in a single passwill depend on the temperature, humidity, and other factors that arebest determined on the job site.

4.1.3 Apply the material in smooth even passes, taking care to keep the spraygun fan pattern at a 90'ngle whenever possible. Reaching with aspray gun will cause the spray pattern to vary from the 90'ngle andwill result in a rougher surface than normal.

4.1.4 Take frequent wet thickness measurements during the application using apenetration measuring device such as those shown in Appendix A to ensurethat the coating is being applied uniformly and at the, required wet filmthickness. These wet thickness checks shall b'e made every five squarefeet or every two running feet of coated surface area. (Note: Whentaking measurements allow for a shrinkage rate of 25% between the wetand the desired dry film coating .thickness.

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4.1.5 Remove excess build up of coating material at edges and points bybrushing or rolling the surface with a damp sponge roller.

4.1.6 Spray edges of the substrate from each side to cause the material towrap around the edge. If the edge coating is not'completely closed,use a wet roller or trowel to seal the edge surface.

4.1.7 Apply Piberglass Armoring to the wet surface after the final pass anduse a roller to flatten out any wrinkles and to embed the fiberglasssecurely. Then apply sufficient material. to cover the embeddedfiberglass.

4.1.8 Remove all runs, sags, drips or other surface imperfections before thematerial cures using wet sponge rollers, brushes or hand trowels.

4.2 Hand A lications

4.2.1 Trowel the material to a uniform thickness using moderate pressureand avoid overworking the material. - The trowel should be wettedwith water when a smooth finish is required.

4;2.2 Glove the material to cables and small pipe using standard workgloves. Work small areas and keep the gloves wet to insure a .

relatively uniform thickness.

,4.3 D Pilm Thickness Measurements .

4.3.1 Take dry film thickness measurements after the applied material hascured. Measurements shall be made using electrical, penetrating ormagnetic measuring instruments.

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4 ' Re air Procedure — Dama e

4.4.1 Remove damaged and loose material using a knife and scrapper. Cutback until sound adhering material is reached.

4.4.2 The edge should be undercut to form a beveled edge as in plasterrepair.

4.4.3 Remove all foreign matter from the substrate using a wire brush.

4.4 ' Spray or 'trowel THERMO-LAG 330-1 onto patch area. Several coat ofthe material can be applied to achieve the desired film thickness.Be sure to allow for shrinkage of repair patch by building up aslight dome shape with the patch.

4.5 Cable Re lacement - Re air

'4.5.1

Remove sections by cutting away material at the side and butt flanges.

4.5.2 Remove fasteners from flanges and carefully remove coated sections.

4.5.3 After work is completed, reattach envelope system using mechanicalfasteners, staples or 18 ga. galvanized tie wires.

4.5.4 Apply a coating of THERMO-LAG 330-1 Subliming Coating in the specifiedwet thickness to the edges and joints of the reinstalled sectionsusing a trowel or stiff bristle brush to fillin any uncoated areas.

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5.0 TOPCOAT APPLICATION

5.1 S ra A lication

5.1.1 Pour Part B into Part A and thoroughly mix using a. mechanical mixer.Mix a minimum of 5 minutes and allow a "sweat in" period'of 20minutes before commencing the application. ~

i

5.1.2 Insure that the area to be topcoated is free from loose and foreign,matter.

5.1.3 Take moisture meter readings of the applied subliming coated surfaceusing a Delmhorst Moisture Meter (Model DP) or equivalent. Obtain areading of 20 or less before applying the topcoat.

5.1.4 Place mixed material into spray rig.

5.1.5 Apply topcoat in a smooth even pattern, making sure to criss-crossthe area in a continuous film.

5.2 Hand A lication

5.2.1 Apply a full smooth coat of topcoating using a long nap mohair roller.Avoid excessive buildup of topcoat in corners and always work to a wetedge of applied topcoat.

6.0 POST APPLICATION PRACTICES

6.1 A clean and orderly condition shall be maintained in the applicationarea. Following the application, all overspray, debris and equipment,shall be removed and the area left in a condition acceptable to theowner.

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7.0 E UIPMENT SUGGESTIONS

7.1 The most economical and satisfactory method of applying THERMO-LAG330-1 Subliming Coating is by either airles or air type sprayequipment.

7.1.1 Air type spray equipment is recomm'ended for use in spraying cabledrops and conduit in order to minimize overspray.

7.1.2 Airless spray equipment is recommended for use in spraying largersections such as cable trays and large I beams.

7.1.3 Suggested complement of spray equipment for both types are shownin Appendix B.

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APPENDIX A

SCHEMATIC OF SUGGESTED PENETRATING

MEASURING DEVICES

h

"A" is equal to the desired thickness of the coating.

On measurement — the pin portion of the gauge must sink completelyinto the layer of the applied coating. Take several readings foreach thickness. Fill the hole created by the gauge after measurementis completed.

24

APPENDIX B

SUGGESTED COMPLEMENT OF REQUIRED SPRAY EQUIPMENT

FOR THERMO-LAG 330-'1'UBLIMING COATING APPLICATION

AIRLESS SPRAY EQUIPMENT

UANTITY DESCRIPTION OF E UIPMENT

1 Each

1 Each

1 Each

1 Each

2 Each

1 Each

1 Each

1 Each

1 Each

1 Each

5 Each

6 Each

Hydra Spray Pump 45:1

Air Powered Ram

Hydra Mastic Spray Gun

Special Dump. Valve

RAC IIIwith 0.55 Tips

Air Agitator

Air Regulator Kit

Air Regulator Only with Gauge

Air Line Filter

Air Line Lubricator

Pump Repair Parts Kits

, Extra Tips with Seals

100= Feet

75 Feet

25 Feet

1 Inch1/2 Inch

3/8 Inch

I.D. Hi Pressure Fluid Hose

I.D: Hi Pressure Fluid Hose

I.D. Hi Pressure Fluid Hose

25;

APPENDIX B

(CONTINUED)

AIR TYPE SPRAY E UIPMENT

UANTITY DESCRIPTION OF E UIPMENT

1 Each

1 Each

1 Each

1 Each

2 Each

1 Each

1 Each

1 Each

1 Each

1 Each

5 Each

10:1 President Spray Pump

Air Powered Ram

Heavy Mastic Spray Gun

Special Dump Valve

1/4 Inch or 1/4 Inch "E" Spray Tip

Air Agitator

Air Regulator Kit

Air Regulator Only with Gauge

Air Line Lubricator

Air Line Filter

Pump Repair Parts Kits

75 Feet

25 Feet

1/2 Inch I.D. Hi-Pressure Fluid Hose

3/8 Inch I.D. Hi-Pressure Fluid Hose

26

APPENDIX C

APPLICATION PROCEDURES

STRUCTURAL STEEL ENTITIES

l.0 INTRODUCTION

This procedure sets for the sequential steps involved in applyingTHERMO-LAG 330-1 Subliming Coating System to structural steelentities and steel storage tanks.

The THERMO-LAG 330-1 Subliming Coating System consists ofTHERMO-LAG Primer, THERMO-LAG 330-1 Subliming Coating, and whereapplicable, THERMO-LAG Topcoat.

2. 0 SURFACE PREPARATION

2.1 All surfaces to be coated are to be clean, dry, above 40'F, andfree from scale, rust and other contaminants.

2.2 Prepare non-compatible surfaces for coating by applying a barriercoat of THERMO-LAG 351 or THERMO-LAG 351-2 Primer'. Never applythe primer directly over a surface previously primed with a zinc .

based primer without installing a barrier coat. Never apply theprimer directly over any hard or glossy paint without rougheningthe surface in accordance'ith standard, good painting, practiceprocedures and make sure that the cleaned substrate is compatiblewith the THERMO-LAG 330-1 Subliming Coating by making cross hatchadhesion tests.

2.3 Blast clean doubtful surfaces to an SSPC-SP6 finish and reprimeimmediately.

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3.0 PRIMER APPLICATION

3.1 Apply the primer- to a properly prepared steel surface in onecontinous coat using spray equipment or a roller. The minimumacceptable dry primer thickness should be 0.002 inches which isnormally achieved by applying at a rate of 200 square feet pergallon.

3.2 Measure primer thickness using an approved magnetic directreading gauge.

3.3 Make cross hatch adhesion tests, as per Federal Standard 141A,on the primed surface to assure proper adhesion between theprimer and the'teel substrate prior to proceeding with theapplication of the THERMO-LAG 330-1 Subliming Coating.

3.4 Make at least one cross hatch adhesion test every twenty (20)square feet of primed surface area. Any primed surface areawhich fails the cross hatch adhesion test shall be sandblastedto an SSPC-SPC6 commercial blast finish and then shall bereprimed with THERMO-LAG 351 or THERMO-LAG 351-2 Primer.

4.0 THERMO-LAG 330-1 SUBLIMING COATING

4.1 Apply the material in as many passes as required to provide therequired film build or thickness, taking care to avoid slumpingor sagging of the coating. The thickness which can be safelyapplied in a single pass will depend upon the temperature,humidity, application technique, and other factors and should bedetermined at the gob site.

4.2 Apply the material in smooth even passes, taking care to keep thespray gun fan pattern at a 90'ngle whenever possible. Reachingwith a spray gun will cause the spray pattern to vary from the

90'ngleand will result in a rougher surface than normal.

28

4.3 Take frequent wet thickness measurements during the applicationusing a penetration measuring device such as those shown inAppendix A to ensure that the coating is being applied uniformlyand at the required wet film thickness. These w'et thicknesschecks shall be made very five square feet or every two running.feet of coated surface area. (Note: When taking measurementsallow for a shrinkage rate of 25%'between the wet and the desireddry film coating thickness.

4.4 Remove excess build up of coating material at edges and points bybrushing or rolling the surface with a damp sponge roller.

4.5 Spray edges of the substrate from each side to cause the materialto wrap around the edge. If the edge coating is not completelyclosed, use a wet roller or trowel to seal the edge surface.

4.6 Apply Fiberglass Armoring, where required, to the wet surfaceafter the final pass and use a roller to flatten out any wrinklesand to embed the fiberglass securely.. Then apply sufficientcoating material to cover the embedded fiberglass.

4.7 Remove all runs, sags, drips or other surface imperfections beforethe material cures using wet sponge rollers, brushes or hand trowels.

4.8 Take dry film thickness measurements after the applied material hascured. Measurements shall be made using'electrical, penetrating ormagnetic measuring instruments.

5.0 . TOPCOAT APPLICATION

5.1 Insure that the area to -be topcoated is free from loos'e and foreignmatter.

5.2 Take moisture meter readings of the applied subliming coated surface'singa Delmhorst Moisture Meter (Model DP) or equivalent.'btain

a reading of 20 or less before applying the to'pcoat.

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5.3 Place mixed material into spray rig.

5.4 Apply topcoat in two continuous coats at a minimum spread rate. of50 square feet per gallon in a smooth even .pattern, making sureto criss-cross 'the area in a continuous film.,

6.0 CLam UP

6.1 A clean and orderly condition shall be maintained in the applicationarea. Following the application, all overspray, debris and equipmentshall be removed and the area left in a condition acceptable to the.owner.

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OUTLINE OF'TSI'S

QUALITY ASSURANCE AND QUAL'ITY CONTROL SYSTEM

EFFECTIVITY AND APPROVAL

NQAP l-l INTRODUCTION

1.1 Scope

1.2 Applicability

1.3 Responsibility

1.4 Definitions

1.5 Documents

NQAP 2-1 QUALITY ASSURA."tCE PROGRAM

2.1 Program Description

2.2 Organization

2.3 Design Control

2.4 Procurement Document Control

2.5 Instructions and Procedures

2. 6 Document Control

2. 7 Procurement Control

2.8 Material Parts and Components Control

2.9 Special Process Control

2.10 Inspection

2:ll Test Control

2..12 Test Equipment Control

2.13

2. 14

Receiving and Storage ControlII

Inspection, Test and Operating Status

I

2.15 Noncomformance Control

2.16 Corrective Action Control

2.17 Quality Assurance Records

2.18 Audits

NQAP.3-1 ORGANIZATION

3.1 Introduction

3.2 Organization Structure

3.3 Responsibilities and Authority

3.4 Internal and External Communication

NQAP 4-1 DESIGN CONTROL

4.1 Introduction

4.2 Applicable Documents

4.3 Responsibility

4.4 Design Documents

4.5 Design Reviews

4.6 Design Interface Control

4.7 Design Changes

4.8 Records

NQAP 5-1 PROCUREMENT DOCUMENT CONTROL

5.1 Introduction

5.2 Responsibility

5.3 Procedures

5.4 Records

NQAP 6-1 INSTRUCTIONS AND PROCEDURES

6. 1 Introduction

6. 2 Responsibility

6.3 Procedures

6.4 Records

NQAP 7-1 DOCUMENT CONTROL

7. 1 Introduction

7. 2 Responsibility

7.3

7.4

Nuclear Quality Assurance Program Manual

Quality Control Procedures

7;5 Other Controlled Documents

NQAP.8-1 PROCURPKNT CONTROL

8.1 Introduction

8.2 Responsibility

8.3 Purchase Requisitions

8.4 Purchasing

8.5 Qualified Vendors

8.6 Records

NQAP 9-1 MATERIAL, PARTS AND COMPONENTS CONTROL

9. 1 Introduction

9; 2 Applicable DocumentsI

9.3 Responsibility

9. 4 Materials

9.5 ., Inspection and Tests

9. 6 Documentation

9. 7 Records

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NQAP 10-1 SPECIAL PROCESS CONTROL

10.1 Introduction

1.0.2 Responsibility

10.3 Special P'rocess'Procedures

10.4 Qualification and Certification of Special ProcessRecord

10.5 Records

NQAP ll-l INSPECTION

11.1 Inspection

11.2 Responsibility

11.3 Procedures

11.4 Records

NQAP 12-1 TEST CONTROL

12.1 Inspection

12.2 Responsibility

12.3 Procedures

12.4 Test Control

12.5 Records

NQAP 13-1 TEST EQUIPMENT CONTROL

13.1 Introduction

13.2 Responsibility

13.3 Operating Procedures

13.4 Measurement Validity

13.5 Identification and Documentation

13.6 Qualifications of Personnel

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13.7'Records

NQAP 14-1 RECEIVING AND STORAGE CONTROL

14.1 Introduction

14.2 Responsibility

14.3 Receiving

14.4 Storage

14.5 Issue

14.6 Shipping

14.7 Records

NQAP 15-1 INSPECTION, TEST AM) OPERATING STATUS

15.1 Introduction

15.2 Responsibility

15.3 Procedures

15.4 Records

NQAP 16-1 DEVIATION AND NONCONFORMANCE REPORTS

16.1 Introduction

16.2 Responsibility

16.3 Deviation and Nonconformance Reports

16.4 Stop Work Authority

16.5 Client Reports

16.6'ecords

NQAP 17-1 CORRECTIVE ACTION CONTROL

17.1 Introduction

17.2 Responsibility

17.3 Procedures

17.4 Records

NQAP 18-1 QUALITY ASSURANCE RECORDS

18.1 Introduction

18.2 Responsibility

18.3 Procedures

18.4 Records

NQAP 19-1

19.1

AUDITS

Introduction

19.2 Applicable Documents

19.3 Responsibility

19.4 Procedures

19.5 Records