Helsel-Fire Resistant Coatings_final.pdf
description
Transcript of Helsel-Fire Resistant Coatings_final.pdf
Presented by:Jayson L. Helsel, P.E.
KTA-Tator, Inc.
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Learning ObjectivesComprehension of the Fire Resistant Webinar willenable the participant to:
Describe how intumescent coatings protect underlying steel from heat exposureIdentify the US authority that evaluates and approves intumescent coatingsList two fire rating classification tests that are used to qualify intumescentcoatings for use in building constructionIdentify two primary resin types that are used to formulate intumescent coatings
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Learning Objectives (cont.)List characteristics of the resin systems used to formulate intumescent coatingsExplain how steel size and structure design affect specified thickness and numberof coatsDescribe the methods used to improve the appearance of the texture ofintumescent coatingsDescribe a method to measure the hardness of the applied coating to assess cureIdentify the generic types of primer and finish coats commonly used inconjunction with intumescent coatings
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Fire Resistant Coatings
Sprayed Fire Resistive Materials (SFRM) are broadgroup of materials including:
Cementitious and gypsum based materialsIntumescent coatings
(Note: There is a separate category for “Fire Retardent”coatings, which are not reviewed here)
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Fire Resistant Coatings
Intumescent Coatings:Are categorized as SFRMsSimilar to conventional coatingsHave unique fire resistant properties
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Intumescent Coatings
How they function:Intumescent coatings char and swell when exposedto fire/heatThe charred layer acts to insulate the steel from fire
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Intumescent Coatings
Performance ratingsCoatings rated by how long steel is protected atspecified thicknessRatings from 1 to 3 hours (at 30 minute intervalsSpecific to shape/size of steel, e.g. W10x 49 column
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Fire Resistance Classifications
Underwriters Laboratories (UL) is recognizedauthority that evaluates and approves intumescentcoatings for a certain classification and fire ratingCertifications can be verified online at www.ul.com
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Fire Resistance Classifications
Certifications are “design” specific by coatingmanufacturerNumbering system defines an alphanumeric designnumber
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Fire Resistance Classifications
BeamsW, M or S shaped steel sections (AISC)Minimum beam size for fire resistance is expressed asW/D ratio
W = weight of beam per lineal footD = perimeter of protection material
Beams of same configuration with greater W/D ratiomay be used in design
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Fire Resistance Classifications
ColumnsMinimum column size and configuration specified in Xand Y series designsSame hourly rating applies when section with equal orgreater W/D ratio is substituted for same configuration
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Fire Resistance Classifications
Beams and ColumnsRequired coating thickness increases as weight of steeldecreases
Lighter steel heats up more rapidly and requires moreprotection
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Fire Resistance Classifications
Intumescent (and Mastic) CoatingsCoating thickness specification in a design is minimumaverage thickness measured in accordance withTechnical Manual 12-B
Average thickness should not exceed maximum thicknesspublished (if listed) in individual designs or byNo individual measurement <80% of specified designthickness
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Fire Resistance Classifications
Technical Manual 12-BPublished by Association of the Wall and CeilingIndustries (AWCI International)Individual measurement = average of 3 gauge readings(similar to SSPC-PA 2)Testing frequency one bay per floor or one test per10,000 square feet (further defines required shapes)
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Fire Resistance ClassificationsTechnical Manual 12-B
ScopeGeneral InformationSubstrate ConditionsSite ConditionsInspection ProceduresMethod of TestsConditions of Finished ApplicationPatching
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Fire Resistance Classifications
ANSI/UL 263Used for resistance to cellulosic fire (e.g. combustion ofwood or building materials)Slower rise in temperature
1000 F at 5 min.; 1550 F at 30 min.; 1700 F at 60 min.; 1925 F at180 min.; 2000 F at 240 min.
Interior and exterior exposures
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Fire Resistance Classifications
ANSI/UL 263 Classified CoatingsTypical use for structural steel in commercial structures
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Fire Resistance Classifications
ANSI/UL 1709Used for resistance to a hydrocarbon fireRapid rise in temperature
2000 F at 5 minutes
Interior and exterior exposuresEnvironmental tests include, accelerated aging, highhumidity, salt spray, thermal cycling for exterior exposure
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Fire Resistance Classifications
ANSI/UL 1709 Classified CoatingsTypical use for steel structures at petrochemcialfacilities, e.g.
Chemical plantRefineriesOffshore oil platforms
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Other Approvals
Intumescent coatings may also need approval by citybuilding codesCoating manufacturers should provide approvals asapplicable
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Generic Coating Types
Intumescent coatings are generally the followinggeneric resin types:
Acrylic/vinylEpoxy
Intumescents are also generally categorized as “thin-film” or “thick-film” coatings
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Generic Coating Types
Acrylic/vinylThin-film coatingSolvent or water-basedSingle componentTypically rated under UL 263
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Generic Coating Types
Acrylic/vinylApplied in several coatsTime-frame for a complete application may span several daysAdditional time may be needed before application of anyrequired exterior finish coat.
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Generic Coating Types
EpoxyThick-film coatingApplied by plural component spray equipment in one or twocoatsRapid cureTypically rated under UL 1709
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Generic Coating Types
EpoxyMay require mesh reinforcement (e.g. metal, fiberglass,carbon)Typically requires the use of applicators licensed or approvedby the coating manufacturer
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Generic Coating ComparisonCoating Type Required
Thickness(mils)
Numberof Coats
RecoatTime
(betweencoats)@50ºF
Time toFinishCoat
@50ºF
Solvent-based acrylic 130 5 24 hours 25 days
Solvent-based vinyl 375 4 4 hours 20+ days
Water-based acrylic 180 6 8 hours 10+ days
Epoxy 180 1 n/a 24 hours
Epoxy w/mesh 340 1-2 n/a 48 hours
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Testing for Coating Cure
Intumescents may require testing for proper cureTypical test is Durometer Hardness (Shore D)
Resistance of coating film to indentation by DurometerinstrumentASTM D2240, “Standard Test Method for RubberProperty-Durometer Hardness”
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Testing for Coating CureClic
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Coating Appearance
Intumescents generally have a rough or orange peelappearanceMethods to improve include:
Back rolling following spray applicationSanding (not recommended)Finish coat application (may be required)
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Coating Systems
Intumescent design approvals typically include aprimer and/or finish coat
When included in design primer/finish must be appliedto meet fire rating
Primer/finish must be endorsed by intumescentcoating manufacturer
Preference always for same manufacturer
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Use of Primers
Intumescent coating manufacturer may have approvedlist of primers
Types include alkyd, acrylic, epoxy and zinc-richApplication thickness important
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PrimersFunction of primer
Provides adhesion to substrateProvides suitable surface for intumescentProvides additional barrier protection
Can also provide inhibitive or sacrificial protection
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Use of Finish Coat
May be required in design approval for exteriorexposureIntumescent coating manufacturer must endorsefinish material
Types include 100% acrylic and aliphatic urethanecoatings
May affect/improve appearance
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Finish CoatsFunction of topcoat
Color and glossAbrasion resistanceChemical resistanceWashabilityResistance to the environment
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Finish CoatsAcrylics
AdvantagesSingle componentEase of applicationColor & gloss retentionFlexibilityLow VOC content for waterbased
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Finish CoatsAcrylics
LimitationsLimited alkali and solvent resistanceModerate abrasion resistanceApplication temperature >50ºF for waterbased
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Finish CoatsUrethanes
AdvantagesColor & gloss retention (aliphatic)AdhesionAcid, alkali resistantChemical resistantImpact/abrasion resistant
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Finish CoatsUrethanes
LimitationsMulti-componentShort recoat intervalsLimited pot lifeMoisture sensitive during cureDifficult to recoat
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Summary of Key Points
When specifying intumescents consider:Required UL approvalCity building code approvalInclude required primer and finish coatsApplicator certification if needed (e.g. plural componentmaterials)Include test sections to evaluate appearance
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Fire Resistive Coatings
Questions?
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