Firemaster. Technical manual. delivering low risk building solutions

Transcription

1 Firemaster Technical manual delivering low risk building solutions

2 Contents About Eurobond Laminates 1 Structural Performance 2 Fire Performance 3 Environmental Performance 4 Thermal & Acoustic Performance 5 Weights, Dimensions & Tolerances 6 Panel Finishes 7 Standard Details Firemaster vertically laid 8 Firemaster horizontally laid 11 Firemaster ceilings 14 Stone wool properties 16 Technical Expertise 18 Eurobond Doors 19 Ceiling panels guidance for use 20 Panel Clamp 21 If you would like any additional information on any of the topics highlighted in this technical manual or project specific technical information not included then please contact us and we would be happy to discuss your requirements Telephone +44 (0) Fax +44 (0) technical@eurobond.co.uk Please note that the information contained in this technical manual is not comprehensive and additional information can be found on our website delivering low risk building solutions

3 About Eurobond Laminates Introduction At the forefront of composite panel design and manufacture for over 25 years, we have built our reputation on quality products that have been expertly manufactured. Our panel systems are engineered to the highest standards to help minimise risk through design, installation, performance in use and end of life disposal. Eurobond offers a comprehensive range of stone wool, architecturally flat composite wall and ceiling panel for both internal and external use. All our panel systems provide built in passive fire protection and are tested and approved where appropriate to LPCB LPS 1181 Part 1 EXT-A, LPS 1208, FM GLOBAL FMRC 4880, BS 476 Part 22 and/or EN 1364 Part 1. We invest heavily in product development, testing and manufacturing technology and operate two of the most technologically advanced panel production lines in Europe, producing consistent, high quality products to exacting tolerances. We also provide a comprehensive technical advisory service to assist in the correct specification, detailing and installation of our products. Certificate No 545a LPS 1208 Certificate No 545b LPS 1181 Part 1 Assessed to ISO 9001:2000 Certificate Number 545 Subject to the conditions of Approval as a Class 1 metal faced wall panel with non-combustible core when installed as described in the current edition of the Factory Mutual Research Approval Guide T +44 (0)

4 Structural Performance Manufactured using metal facings bonded to a high density structural stone wool core, Eurobond s panels offer exceptional spanning characteristics. Eurobond s panel strength characteristics have been calculated following the European recommendations for Sandwich Panels: TWG 7.4.ECCS W56; including a load safety factor of 1.5 and material safety factor of Maximum allowable spans (m) for internal walls & ceilings Product Panel thickness (mm) Firemaster Wall Lite Firemaster Wall Extra Firemaster Wall Ultima Firemaster Ceiling Wall panel calculations are based on a uniformly distributed load of 0.25 kn/m 2. Ceiling panel calculations are based on BS6399 using a uniformly distributed load of 0.25 kn/m 2 plus a point load of 0.9 kn. Please note the above spans are based on the cold state structural performance of the panels. Where fie resistance is required the allowable spans may need to be reduced to ensure the fie resistance is maintained. These allowable spans are shown opposite in Fire Performance. 2 delivering low risk building solutions

5 Fire Performance Fire performance should be judged on both fire resistance and reaction to fire. Firemaster panels have been tested/assessed to BS476 Part 22, for fire resistance and independently approved for reaction to fire by the Loss Prevention Council to LPS1181 and LPS1208 and by Factory Mutual to Standard Fire resistance Fire resistance is generally a requirement of Building Regulations but can also be used when compartmentation within buildings is required, it is measured in terms of: i ii Integrity the ability of a system to prevent the penetration of hot gases and flames. Insulation the ability of the system to reduce the temperature rise on the unexposed side of the fire and therefore prevent fire spread through radiated heat. When considering the fire resistance of a panel system it is important to refer to both integrity and insulation. Some foam-cored cladding systems, when used with cover strip flashings, intumescent and stitching of the joints, can achieve reasonable levels of integrity but not insulation. This increased level of integrity is often mistakenly taken as fire resistance. However, without the insulation values it is of limited use. Also the use of additional cover strips, intumescent and stitching of the joints is often unacceptable from an installation and aesthetic point of view. This leads to instances where although specified, the additional cover strips, etc. are not fitted. Firemaster panels require NO additional components in order to achieve the excellent ratings shown in the table below. Product Panel thickness Fire resistance (minutes) Maximum unsupported length (m) (mm) Insulation Integrity LPS 1208 BS476 Pt Firemaster Wall Lite * Firemaster Wall Extra * *** Firemaster Wall Ultima** Firemaster Ceiling ** Firemaster panels used in a wall application will provide equal fire performance from both sides i.e symmetrical fire performance. ALL panels can be fitted vertically or horizontally. * Joint stitched on both sides at 3m centres ** Panel joint stitched on both sides at 300mm centres *** 0.7mm faces to both sides T +44 (0)

6 Environmental Performance As a responsible UK manufacturer, Eurobond is justifiably proud of it s environmental record and recognises the importance of sustainable construction. Our philosophy is one of continual improvement and we strive to manufacture the most environmentally responsible products available whether that is through Life Cycle Assessment (LCA), implementation of Environmental Management Systems or the demonstration of a truly sustainable approach. WRAP Approved Recycling Eurobond has been given the seal of approval by leading recycling government backed organisation WRAP (Waste & Resources Action Programme). In independent tests WRAP found Eurobond s products are fully and independently recyclable, allowing new stone wool cored composite panels to be made diverting waste from landfill. Life Cycle Assessment Full Life Cycle Assessments are available on all Eurobond products and help to quantify the total environmental impact. End of Life Solutions & Recycled content The construction sector is the largest producer of waste to landfill in the UK, Eurobond recognise that a more efficient use of materials would help to minimise the environmental impact of construction, reducing carbon emissions by diverting materials from landfill and limiting the depletion of finite natural resources. As such we advocate a 'Cradle to Cradle' approach to recycling where materials are recycled in a closed loop. This maximises material value whilst minimising the damage to ecosystems - products are used, recycled and re-used again without losing any material quality. This ensures that all materials used in the manufacture of Eurobond panels have a high content of recycled materials. The separated steel and stone wool are returned to their respective manufacturers and entered back into the supply chain as undiminished materials. Eurobond's stone wool composite panels pose minimal impact to the environment as they rely upon trapped air to attain their thermal properties. Stone wool is manufactured from diabase rock, a natural resource found in abundance around the world. If you would like further information on the performance credentials of Eurobond's panels please contact our technical team on or us at technical@eurobond.co.uk 4 delivering low risk building solutions

7 Thermal and Acoustic Performance Thermal Performance: Eurobond panels have been specifically designed to meet the as built thermal requirements of the Building Regulations and/or Technical Handbooks in England and Wales, Scotland and Northern Ireland. U-value calculations (W/m 2 K) Panel thickness (mm) Firemaster Wall Lite Firemaster Wall Extra Firemaster Wall Ultima 0.26 Firemaster Ceiling The above U values have been calculated using a plain element approach and do not take into account any thermal bridging through the joint. If you require composite panels to be used as external cladding, please refer to our Europanel and Rockspan Technical Manual. Based on a stone wool core with a k value of W/mK for Lite and W/mK for Extra Typical example of a Trisco Thermal Model for Firemaster [ C] All figures have accounted for any thermal bridging at the interlocking joint. Acoustic Performance: As buildings all need some form of acoustic control to meet specific client and/or regulatory requirements (Building Regulations Approved Document E), the following guidance is intended to provide the architect, designer, acoustic engineer and end user with qualification of Firemaster performance in England and Wales, Scotland and Northern Ireland. Weighted sound reduction index Rw (db) Panel thickness (mm) Firemaster Wall Lite Firemaster Wall Extra Firemaster Wall Ultima 32.7 Firemaster Ceiling Airborne sound transmission Reflection reverberation Rain impact sound transmission Flanking All calculations are based on the following panel construction: External face: 0.5mm thick steel Noise source Noise source Flanking Core: Internal face: 99Kg/m 3 stone wool for Firemaster Wall Lite 135Kg/m 3 stone wool for Firemaster Wall Extra and Ultima and Ceiling 0.5mm steel The information shown above is based on The Metal Cladding and Roofing Manufacturers Association (MCRMA) acoustic performance software provided by the University of Salford Acoustic Department and is fully substantiated by tests carried out by the C.S.T.B Paris. T +44 (0)

8 Weights, dimensions and Tolerances Firemaster Panel thickness Firemaster Firemaster Firemaster Firemaster (mm) Wall Lite Wall Extra Wall Ultima Ceiling Sizes available (mm) Length Width 1200 Thickness Flatness tolerance 1.5 mm from the theoretical flat plane over a distance of 700mm Joint details Nominal 2mm Panel Module Panel Thickness Structural Stone Wool Core 1 200mm Standard Module 6 delivering low risk building solutions

9 Panel finishes The panels are available with the following steel face finishes 1. Foodsafe laminate 2. Primer coated galvanised 3. White/grey polyester 4. Stainless Steel 304 The following face profiles are available: Architecturally flat Minibead finish T +44 (0)

10 Standard details Firemaster vertically laid Eurobond have a comprehensive library of standard details that cover Firmaster in both horizontal and vertical applications. NB: Always check with our web site for the latest version of any drawing. These details are available as PDF files, they are also available as DWG format to allow them to be directly imported into project-specific drawings. Stone wool core Floor Channel 8 delivering low risk building solutions

11 Standard details Firemaster vertically laid (continued) Firemaster interlocking joint detail FMV-01A Silicone seal 0.5mm coated steel face 0.5mm coated steel face Structural stone wool core Nominal 2mm Typical wall/floor junction FMV-05A 50mm deep food safe laminate channel (width of panel to suit panel thickness) bedded on butyl mastic secured with hammer fixings at 900mm centres. All joints sealed as required T +44 (0)

12 Standard details Firemaster vertically laid (continued) Typical wall/beam junction with 50mm deflection allowance FMV-07A Supporting steelwork fire protected as required by others Deflection zone (typically 70mm) stone wool insulation (minimum density 23kg/m 3 ) Self tapping fastener fixed through 55mm slotted hole. Fastener must still allow panel to slide relative to 2mm galvanised channel 2mm powder coated galvanised channel with 55mm slotted holes (at 300mm centres) to allow for 50mm deflection of concrete soffit Wall/ceiling junction detail FMV-08B M12 threaded suspension rod Typical Ø40mm spreader washer 50 2mm galvanised angle fixed to panels at 300mm centres 50 50x50x2mm galvanised angle fixed to panels at 300mm centres Ø5.5mm self drilling self tapping steel fasteners Internal flashing fixed at 300mm maximum centres. All junctions sealed with silicone sealant 10 delivering low risk building solutions

13 Standard details Firemaster horizontally laid Eurobond have a comprehensive library of standard details that cover Firmaster in both horizontal and vertical applications. NB: Always check with our web site for the latest version of any drawing. These details are available as PDF files, they are also available as DWG format to allow them to be directly imported into project-specific drawings. Stone wool core Floor Channel T +44 (0)

14 Standard details Firemaster horizontally laid Base detail 1 FMH-05A 2mm galvanised base channel support fixed to floor slab at maximum 600mm centres Horizontal joint detail FMH-01A Structural stone wool core Vertical support steelwork Nominal 2mm Panel module 12 delivering low risk building solutions

15 Standard details Firemaster horizontally laid (continued) Typical wall/beam junction with 50mm deflection allowance FMH-07A Supporting steelwork fire protected as required by others stone wool insulation (minimum density 23kg/m 3 ) Self tapping fastener fixed through 55mm slotted hole. Fastener must still allow panel to slide relative to 2mm galvanised channel Deflection zone (typically 50mm) 2mm powder coated galvanised channel with 55mm slotted holes (at 300mm centres) to allow for 50mm deflection Typical corner detail FMH-08A 50x50x5mm steel angle bracket fixed to main steelwork Extended corner flashing fixed to panel at 300mm centres Vertical steelwork fire protected as required by others Any voids filled with stone wool insulation (minimum density 23kg/m 3 ) T +44 (0)

16 Standard details Firemaster ceilings Interlocking joint detail FMC-01A Silicone seal 0.7mm coated steel face Nominal 2mm 0.5mm coated steel face Structural stone wool core Joggled top hat suspension detail vertical section FMC-05A 125mm steel cover strip secured with 4 x 13mm stainless steel rivets at 300mm maximum centres All junctions sealed with silicone 45 x 70 x 2mm galvanised connector 400mm long Galvanised joggled top hat secures to both panels with 4x13mm stainless steel rivets at 500mm maximum centres 62 For lengths greater than 3000mm use an M12 connector M12 nylock nuts 2 off stone wool infill must be used (minimum density 23 kg/m 3 ) 200mm cover strip All junctions sealed as required Optional Ø4x13mm stainless steel rivet to positively located cover strip full M12 hex nuts & 2 M12 flat washers 14 delivering low risk building solutions

17 Standard details Firemaster ceilings (continued) Joggled top hat suspension component details FMC-03C Joggled top hat Top hat connector 400mm long cover strip full and 2 half holes Ø14mm Ø5mm holes 16 off at 300mm centres Ceiling Suspension detail FMC-04A M12 nylock nuts 2 off For lengths greater than 3000mm use an M12 connector Continuous bituthene tape to maintain vapour seal Cover strip in CLAQ finish secured with Ø4mm x 16mm plain aluminium rivets at 450mm maximum centres. All junctions sealed as required stone wool infill M12 nylock nuts 2 off M12 washer White plastic necked washer White plastic snap on cover 2mm galvanised channel powder coated white RAL 9016 fixed to both panels at 300mm centres with Ø4mm stainless steel rivets 3mm washer Ø20mm inside & Ø50mm outside M12 washer T +44 (0)

18 Stone wool properties In the past, due to its appearance and texture, doubts have been raised about the suitability of stone wool when used in food environments and when in contact with installers and the general public. Eurobond, in conjunction with Rockwool, have had a series of independent tests carried out to prove the safety and suitability of stone wool. Promotion of bacterial growth Through Campden & Chorleywood Food Research Association Group two tests were carried out to show that Rockwool does not promote bacterial growth: i. Japanese Seal method (Test Report No. FH/67949/1) The results of this test showed that using an example of typical food industry Gram of negative (E.coli) and Gram positive (S.aureus) bacteria, there was no evidence to suggest that Rockwool sustained more microbial growth than other control materials and may potentially inhibit the growth of some micro-organisms. Water absorption properties of Rockwool (Test Report No. FH/67949/2) Through Campden & Chorleywood Food Research Association Group a test was carried out which showed that when water was placed onto the surface of the Rockwool, a distinct ball formed showing the material is hydrophobic. Once the head of water is sufficient to overcome the surface tension holding the water on the surface, the Rockwool becomes leaky and allows the water through. There does not appear to be any wicking or capillary effect. ii. Injection method (Test Report No. FH/67949/3) From the results obtained it can be concluded that Rockwool does not promote growth of L.monocytogenes, P.aeruginosa and S.cerevisiae when injected into the material. In fact the counts decreased in Rockwool compared with PB controls. In summary, using examples of typical food microorganisms, there was evidence to suggest that microbial counts decrease when injected into Rockwool. 16 delivering low risk building solutions

19 Stone wool properties Performance Stone wool is manufactured from a volcanic rock to which coke and limestone are added. The molten material is spun into wool and small quantities of resin binder and mineral oil are added to lock the strands together and make them water repellent. The wool is formed into a mat, which is then carried through ovens where it is cured and compressed giving it good structural strength. This mat is used as the core for the Firemaster panel. Stone wool has outstanding properties and performance that make it especially suitable for the Firemaster Panel: Fire Superb fire properties and rated A1, the safest under the new Euroclass Reaction to Fire Insulation stone wool has excellent thermal and acoustic properties Biological stone wool is completely rot proof and does not encourage the growth of mould or bacteria Stone wool non-carcinogenic properties UK and European legislation The safety of stone wool insulation is confirmed by UK and EU health and safety legislation whereby stone wool is free from suspicion of carcinogenic effects, ie is not classified as a possible human carcinogen (UK HSE CHIP Regulations and European Directive 97/69/EC). A unique feature of stone wool fibres is that they are biosoluble any fibres that are possibly inhaled are soluble in the human body but are not sensitive in this respect to humidity or other liquids outside the body. Fraunhofer ITA certificate no. 02G98006A details the results of tests undertaken on Rockwool stone wool in accordance with the required EU method. These results confirm that it is not necessary to classify Rockwool fibres under UK and EU regulations. Environment No CFCs or HCFCs used in manufacture and it is fully recyclable Water Resistance stone wool repels water. The vapour resistance is negligible and usually considered to be the same as that of air T +44 (0)

20 Technical Expertise To assist in correct specification, detailing and installation of our products, Eurobond provide a comprehensive Technical Service which can assist in a variety of areas: Project Specific Design Advice As well as the standard information and range of details available, project specific information can be developed to cover: Load/span calculations Development of bespoke CAD details In Depth Fire Performance Knowledge Eurobond has extensive knowledge of the performance of composite panels in fires. We have carried out a wide range of recognised and bespoke fire tests, as well as working closely with acknowledged fire experts. This enables us to: Provide guidance in selecting the most appropriate products to achieve the required fire performance Provide correct detailing for each product Advise on the Building Regulations and insurance company specific fire requirements Typical load/span calculation table Internal Walls External face Material steel Gauge 0.5 mm Core Lite, Extra or Ultima extra Thickness 100 mm Internal Face Material steel Gauge 0.5 mm Width of supporting steelwork Span - steelwork centres 50 mm 6 m External Temperature 20ºC Internal Temperature 10ºC Deflection limit 100L/? Results Maximum Allowable UDL Pressure 0.62kN/m 2 Maximum Allowable UDL Section 0.62kN/m 2 All Eurobond products are: BREEAM-ready with Life Cycle Assessment to ISO Fully compliant with relative Building Regulations and Technical Handbooks High in recycled content Fully recyclable Training We employ dedicated applications engineers to carry out on site training and also conduct a more comprehensive range of training courses at either customer premises or at our factory in Cardiff. This includes: Product application and installation training to ensure the correct specification and use of Eurobond products Pre-installation project guidance Project detail confirmation Sign-off and project completion reports Eurobond has its own in house research and development staff who are continually seeking to improve the performance of existing products and develop new ideas. Experience gained through research and development allows Eurobond to speak with authority on the performance of our panel systems, confident in the knowledge that advice given is based on information gained through testing, prototyping and practical experience. Members of Eurobond s Technical Department are available to attend site meetings to provide expert technical advice at the design stage, during installation and post-installation. 18 delivering low risk building solutions

21 Eurobond Doors Eurobond Doors is a sister company of Eurobond Laminates and is a leading designer and manufacturer of composite doors, supplying a range of doors for a variety of applications and due to the quality, technology and performance of the doors they are consistently specified for a wide range of industries. Personnel doors Insulated doors Fire doors In-house design allows us to provide the perfect solution for external and internal door applications. Eurobond combines functionality with outstanding aesthetic appeal, for use in commercial, industrial and public environments. Doors are available in single, double and unequal configurations. Options are also available for side panels, over panels, vision panels and louvers where applicable. The doors are specifically designed for incorporation into Eurobonds panel systems. A range of standard detail drawings are available via the Eurobond Doors website and technical department to allow easy specification of doors as part of your Eurobond building envelope. If you would like further information please contact our sales team on or visit T +44 (0)

22 Ceiling panels guidance for use The exceptional performance of Firemaster Ceilings has made the use of stone wool ceiling panels a practical proposition for specifiers and contractors alike. However, the abuse of the walk on capacity of Firemaster Ceilings must be avoided and therefore the following guidelines must be strictly adhered to: How the law applies The erection of insulated panel ceilings or subsequent maintenance and access operations come under health and safety law and this requires hazards to be identified and where possible, eliminated. Any residual risks should be assessed and safe systems of work developed to minimise them. Remember, having a safe system of work when undertaking work on a ceiling is a legal duty and should be a co-operative effort between Client, Contractor and Designer. How the law applies Provide dedicated and safe access onto the ceiling and ensure that all persons access the ceiling from these point(s) only. Whenever possible, access should be via a stair-tower. However, if ladders are used they should be tied at the top and extend at least 1.1m past the access point. Personnel must not jump or bounce on ceilings and should not gather in groups of more than two. Signs should be erected at all points of access. Provision of access to maintain the roof Where access is required to the ceiling area to inspect or maintain plant, designated walk ways must be used. These could take the form of an independently supported walk way which gives access to the necessary plant. Where a walk way cannot be installed but access is still required, the ceiling must be protected with 6 mm ply/hardboard to spread loads. These boards should be fixed to the back of the ceiling panels with self tapping screws and positioned: Fixing the ceiling Always fix ceiling panels in accordance with Eurobond s recommendations, e.g. sequence of laying down the panels, number of fixings, etc. Never allow partial fixing only of ceiling panels. Each panel should be fully fixed, allowing progress of the work as it is laid down, with the correct number of fixings as required and system of support. If any cut outs for penetrations over 100mm wide are required this must have prior approval of Eurobond. Post construction maintenance Like any other product, Eurobond ceilings will perform better and for longer if you maintain them properly. But remember the hazards in maintaining a ceiling or using it for access can be greater than for constructing them. Do not allow any person access to a ceiling without vetting their skills and safety methods. Do not allow untrained employees to pop up for a quick look or to carry out quick repairs. Remember Contact Eurobond if in doubt on any aspect of new ceiling construction or subsequent access. The Best Practice Guide for work on ceilings constructed with steel faced insulated composite panels is also available upon request. Close to and running parallel with the ceiling suspension system At the Perimeter of the ceiling where the ceilings panels are fixed back to the walls. NB Should anything other than normal maintenance access be required, Youngman s type walk boards should be used by all subcontractors at all times. 20 delivering low risk building solutions

23 Panel Clamp Standard details for Horizontally laid Firemaster Panels Eurobond recommends the use of our patented panel clamp for safe and easy installation of panels. The panel clamp is perfect for installing our Europanel, Rockspan and Firemaster range of panels, when laid horizontally. Clamps are available to suit all panel thicknesses. Each pair of clamps has a safe working load of 500 kg, which allows them to safely lift even the longest panels that Eurobond can currently supply. The clamps work by gripping the flanges on the top of the panel by means of a cam and wedge mechanism. A half turn of the actuating lever is all that is required to lock the clamp onto the panel. Safety features are a spring loaded pin that holds the cam in the locked position, a mechanism that tightens the grip on the panel during lifting and in the unlikely event that there is a failure of the panel or the clamp, a set of safety strops that will stop the panel from falling. The clamps are designed to offer an easy installation of horizontally laid panels whilst maintaining the highest levels of safety. The clamps are suspended from the lifting beam by links that allow them to rotate in the horizontal plane, making it possible to pick-up panels directly from the stack as delivered with the minimum of manual handling. Lifting methods can either be a crane or a telehandler as shown below. The Benefits of Mechanical Handling Techniques Increased productivity - realistic installation of up to 600m 2 of panel a day Full compliance with H&S and CITB due to the removal of manual handling on site Time savings - being able to install up to 600m 2 of panel a day allows for earlier project completion, meaning contractors are able to complete more projects in a year Significant labour cost savings are provided, through reduced labour and faster completion on site Reduced damage to panels on site Panel Clamp Components 3m spreader beam Set of safety strops 2 clamps Safety chain D shackles Delivered in a toolbox Each clamp is CE marked and comes with an instruction booklet. If you would like further information on our panel clamps or require additional installation information please contact our technical team on or technical@eurobond.co.uk T +44 (0)

24 Eurobond Laminates Ltd Wentloog Corporate Park Cardiff CF3 2ER Telephone: +44 (0) Fax: +44 (0) Ref: FTM - 9/11 In association with our strategic trading partners Rockwool, Leeson and Tata Steel. delivering low risk building solutions 22