BRE Global Assessment Report

Transcription

1 BRE Global Assessment Report An assessment of the fire performance of the Gebrik Insulating Brick Cladding System against BR 135, Third Edition Prepared for: Date: 13 April 2016 Aquarian Cladding Systems BRE Global Ltd Watford, Herts WD25 9XX Customer Services From outside the UK: T + 44 (0) F + 44 (0) E enquiries@bre.co.uk Prepared for: Aquarian Cladding Systems Eversea Business Centre 13 Gardens Road Clevedon Somerset BS21 7QQ

2 Prepared by Name Position Andrew C Russell Senior Consultant Date 13 April 2016 Signature Authorised by Name Position Richard A Jones Associate Director Date 13 April 2016 Signature Date of this report 13 April 2016 Date of next review 13 April 2021 This report is made on behalf of BRE Global and may only be distributed in its entirety, without amendment, and with attribution to BRE Global Ltd to the extent permitted by the terms and conditions of the contract. Assessment results relate only to the specimens tested. BRE Global has no responsibility for the design, materials, workmanship or performance of the product or specimens assessed. This report does not constitute an approval, certification or endorsement of the product assessed and no such claims should be made on websites, marketing materials, etc. Any reference to the results contained in this report should be accompanied by a copy of the full report, or a link to a copy of the full report. BRE Global s liability in respect of this report and reliance thereupon shall be as per the terms and conditions of contract with the client and BRE Global shall have no liability to third parties to the extent permitted in law. Commercial in Confidence BRE Global Ltd 2016 Page 1 of 19

3 Table of contents 1 Introduction 3 2 Scope 4 3 Supporting data BRE test report no Issue: BRE classification report no Issue: BRE test report no. P Issue: BRE classification report no. P Issue: Description of the proposed systems 9 5 Assessment General Layer 7 Kingspan Kooltherm K5 and K15 insulation board Layer 6 Outer sheathing board Layer 5 Cavity (proposal 1 only) Layer 4 Inner sheathing board (proposal 1 only) Layer 3 Structural framing systems (SFS) Proposal 1 (with cavity) Proposal 2 (without cavity) Layers 1 and 2 Internal plasterboard lining 13 6 Conclusion 14 7 Figures 15 8 Validity of the assessment Declaration by applicant BRE Global declaration 19 Commercial in Confidence BRE Global Ltd 2016 Page 2 of 19

4 1 Introduction Fire tests in accordance with BS :2005 have been successfully carried out on Gebrik Insulating Brick Cladding Systems. This assessment report considers the performance of these systems when incorporating variations to the tested designs. Commercial in Confidence BRE Global Ltd 2016 Page 3 of 19

5 2 Scope This assessment report considers the fire performance of the Gebrik Insulating Brick Cladding System against the criteria of BR 135, Third Edition, if tested in accordance with BS :2015. Commercial in Confidence BRE Global Ltd 2016 Page 4 of 19

6 3 Supporting data 3.1 BRE test report no Issue: 1 A fire test in accordance with BS :2005 was carried out on a Gebrik system on an SFS substrate on 08 April The system, as built, comprised of: Double layer of 12.5 mm wall board. 150mm steel frame insulated with 140mm mineral wool insulation. 12mm Cement calcium sheathing board. Breather membrane. 15mm timber battens. Intumescent expanding fire break. 12mm Cement calcium sheathing board. 60mm K5 insulation board. 60mm Gebrik panel with bonded brick slips. A sectional steel frame system (SFS) was installed between the floor slabs on the main cladding wall 4, with horizontal base and head tracks fixed to the concrete and steel substrate. Vertical rails were installed at nominal 600mm centres to form the steel frame. A double layer of 12.5mm Gyproc wall board was installed on the rear of the SFS and a single layer of cement based calcium sheathing board was fixed to the front of the SFS. The void within the steel frame was filled with 140mm of mineral wool insulation. A single layer of breather membrane was attached to the sheathing board. An array of 15mm rated timber battens was installed vertically and equally centred and mechanically fixed to the sheathing board. A second layer of sheathing board was attached to the timber battens to form a drainage cavity. At 2400mm and 4800mm from floor level a break in the sheathing board was formed and a continuous strip of intumescent expanding fire break fixed back to the first layer of sheathing board. A single layer of 60mm Kingspan Kooltherm K5 External wall board was mechanically attached to the sheathing board with single fixing and stainless steel washer placed in the centre of each board. A 60 mm single layer of Gebrik was mechanically fixed through the K5 insulation into the sheathing board through hidden fixing at a rate of 9 per whole panel and 5 on corner panels. Commercial in Confidence BRE Global Ltd 2016 Page 5 of 19

7 3.2 BRE classification report no Issue: 1 This report presents the classification of the system tested in BRE report no Issue: 1. The classification is carried out in accordance with the procedures given in BR 135 Fire performance of external thermal insulation for walls of multi-storey buildings, Third edition, Annex B The system, as tested, satisfied the criteria as follows: Results Test method & test number Parameter No. tests Fire spread test result time, ts (min) Compliance with parameters in Annex B BR135:2013 External fire spread >15 minutes Compliant BS : 2005 BRE Issue: 1 Internal fire spread Insulation layer 1 >15 minutes Compliant Internal fire spread Burn through >15 minutes Compliant 3.3 BRE test report no. P Issue: 2 A fire test in accordance with BS :2005 was carried out on a Gebrik Rainscreen Cladding System on 15 July The test specimen was installed onto face 4 of the BRE Global External Cladding Test Facility. This is a multi-faced test facility constructed from steel, with the cladding system affixed to the steel substructure. The build-up of the system (in order from the structural frame to the outer panels) comprised of: Double layer of 12.5mm plasterboard 150mm light gauge steel frame (Kingframe)/150mm Earthwool Flexi rock mineral wool insulation 12mm calcium silicate based cement building board (Y-wall) 15mm fire retardant battens 12mm calcium silicate based cement building board (Y-wall) 120mm K15 Kingspan insulation 1000mm x 75mm VRB Lite intumescent fire component installed both vertically and horizontally 60mm Gebrik panels, consisting of 43mm rigid polyurethane foam insulation (PUR) and 17mm façade brickslips and mortar Further detail of the composition of the wall is given below: A sectional light gauge steel frame system (SFS) was installed between the floor slab hangers on the main cladding wall 3, with horizontal base and head tracks fixed to the steel substrate. Vertical rails were installed at varying centres to accommodate the cladding system on to the test rig. Within the SFS was installed a 150mm layer of Earthwool Flexi. Commercial in Confidence BRE Global Ltd 2016 Page 6 of 19

8 A double layer of 12.5mm plasterboard was installed on the internal face of the SFS and a single layer of calcium silicate based cement building board was fixed to the front of the SFS. 15mm fire retardant battens were installed on the front of the calcium cement sheathing board, and on these was fixed a second layer of calcium silicate based cement building board. The insulation was directly fixed to the sheathing board using Ø4.8mm fixings and washers, including 2no stainless steel washers. The joints between the individual sheets were taped with aluminium tape. The insulation was 120mm Kingspan K15 panels supplied in 2.4m x 1.2m sheets. The Gebrik cladding system was mechanically fixed directly into the sheathing board through Isofixing washers, precast in the panels and corners, and through the K15 using Gebrik system fixings. A horizontal starter rail was installed at the base, which located the bottom of the first row of brick cladding panels and corners. The panels and corners were then installed row by row up the façade until the entire test area was fully clad. Once mechanically fixed, the horizontal and vertical chambers between panels and corners were fully filled with expandable PU foam prior to the stitching slips being applied with cement-based system adhesive. The entire façade was then pointed with mortar and allowed to cure for 13 days. The horizontal and vertical firebreaks located within the cavity were VRB Lite barriers, measuring 1000mm x 75mm, and were installed in the following locations: Horizontal fire breaks were installed above the hearth (for the width of the main wall), approximately 900mm above the hearth (full width of main and wing walls), and aligned with the top of the level 2 floor, and a final barrier was installed to close off the top of the system. A vertical firebreak was installed on the main wall to the left hand side of the hearth (between the wing and main walls) for the full height of the system. This was located approximately 430mm from the cement particle sheeting board layer on the wing wall. A second vertical fire break was installed on the wing wall for the full height of the system. This was located approximately 215mm from the cement particle sheeting board layer on the main wall. A third vertical fire break was installed to the right of the hearth and terminated at the horizontal fire break across the top of the hearth. This was approximately 450mm from the right hand edge of the system. The hearth opening was faced with a 120mm deep Gebrik head reveal to close the system and K15 insulation. The cavity was closed with the fire treated timber batten applied horizontally and the SFS was clad with calcium cement board. 3.4 BRE classification report no. P Issue: 2 This report presents the classification of the system tested in BRE report no. P Issue: 2. The classification is carried out in accordance with the procedures given in BR 135 Fire performance of external thermal insulation for walls of multi-storey buildings, Third edition, Annex B Commercial in Confidence BRE Global Ltd 2016 Page 7 of 19

9 The system, as tested, satisfied the criteria as follows: Results Test method & test number Parameter No. tests Fire spread test result time, ts (min) Compliance with parameters in Annex B BR135:2013 External fire spread >15 minutes Compliant Internal fire spread Insulation layer >15 minutes Compliant BS : 2005 BRE P Issue: 2 Cavity behind insulation 1 >15 minutes Compliant Cement particle board >15 minutes Compliant Internal fire spread Burn through >15 minutes Compliant Commercial in Confidence BRE Global Ltd 2016 Page 8 of 19

10 4 Description of the proposed systems The construction of the proposed wall systems are similar to those tested and comprise the following layers: Table 1 Tested and proposed systems Layer Tested Proposal 1 (with cavity) Proposal 2 (without cavity) mm Knauf Wallboard Any plasterboard Any plasterboard mm Knauf Wallboard Any plasterboard Any plasterboard 3 150mm structural framing system with 140mm stone mineral wool insulation 75mm to 200mm SFS with no insulation, stone mineral wool insulation, phenolic insulation, PUR insulation or EPS insulation 75mm to 200mm SFS with no insulation, stone mineral wool insulation, phenolic insulation, PUR insulation or EPS insulation 4 12mm cement sheathing board Minimum 9mm cement sheathing board, calcium silicate board, exterior grade plywood or Oriented Strand Board (OSB) Minimum 9mm cement sheathing board, calcium silicate board, exterior grade plywood or Oriented Strand Board (OSB) 5 15mm cavity with fire treated birch plywood battens with Tenmat FF102/15 1 or AIM VRB Lite 2 intumescent cavity barriers Minimum 15mm cavity with fire treated birch plywood battens, aluminium battens/brackets, steel battens/brackets with no insulation, stone mineral wool insulation, polyurethane insulation or phenolic insulation and Tenmat FF102/15 or AIM VRB Lite intumescent cavity barriers No cavity 6 12mm cement sheathing board Minimum 9mm cement sheathing board or calcium silicate board No cement sheathing board 7 60mm Kingspan Kooltherm K5 insulation board 1 120mm Kingspan Kooltherm K15 insulation board 2 Up to 70mm Kingspan Kooltherm K5 insulation board Up to 120mm Kingspan Kooltherm K15 insulation board Up to 70mm Kingspan Kooltherm K5 insulation board Up to 120mm Kingspan Kooltherm K15 insulation board 8 60mm Gebrik Insulating Brick Cladding System 3 60mm Gebrik Insulating Brick Cladding System 60mm Gebrik Insulating Brick Cladding System Commercial in Confidence BRE Global Ltd 2016 Page 9 of 19

11 Notes: 1. The specimen tested in BRE test report no Issue: 1 incorporated Tenmat FF102/15 cavity barriers and 60mm Kingspan Kooltherm K5 insulation board. 2. The specimen tested in BRE test report no. P Issue: 2 incorporated AIM VRB Lite cavity barriers and 120mm Kingspan Kooltherm K15 insulation board. 3. The specimen tested in BRE test report no. P Issue: 2 included Iso-fixings, which are polyamide washers cast into the Gebrik system to improve thermal performance and wind load resistance. Typical examples of the system with a cavity (proposal 1) are shown in figures 1 and 2 and typical examples of the system without a cavity (proposal 2) are shown in figures 3 and 4. Commercial in Confidence BRE Global Ltd 2016 Page 10 of 19

12 5 Assessment 5.1 General During the tests on the systems tested in BRE report nos Issue: 1 and P Issue: 2, the maximum external air temperature at level 2 remained below the limit of 600 C within 15 minutes of the start time, as did the temperature at the mid-depth of the insulation, at the mid-depth of the outer layer of cement sheathing board and at the mid-depth of the cavity. The approximate maximum temperatures in each test at each of these locations within the first 15 minutes are tabulated below: Table 2 Maximum temperatures measured at level 2 in tested systems BRE report no Issue: 1 (60mm Kingspan K5) BRE report no. P Issue: 2 (120mm Kingspan K15) Air temperature 380 C 390 C Gebrik panels 110 C K5/K15 insulation 105 C 90 C Cement sheathing board 130 C 50 C Cavity 100 C 40 C 5.2 Layer 7 Kingspan Kooltherm K5 and K15 insulation board The systems were tested with 60mm-thick Kingspan K5 (BRE report no Issue: 1) and 120mmthick Kingspan K15 (BRE report no. P Issue: 2). We have been advised by Kingspan Insulation that these two products have an identical formulation. The only difference is that K15 is foilfaced and K5 is tissue-faced. As the temperature at the mid-depth of the Gebrik panels was only 110 C, it is clear that the temperature of the Kingspan K5 or K15 insulation board will not be significantly different regardless of thickness. Therefore, both products are considered suitable for any thickness up to the maximum tested, although it should be noted that the maximum thickness available for K5 is only 70mm. 5.3 Layer 6 Outer sheathing board The tested systems each incorporated cement particle sheathing board. During the tests, the maximum temperature of this layer was 130 C when using 60mm Kingspan Kooltherm K5 insulation and 50 C when using 120mm Kingspan Kooltherm K15 insulation. These temperatures are sufficiently low to suggest that any alternative non-combustible sheathing board could be used, e.g. calcium silicate board. Reducing the board thickness to 9mm should have no significant impact at these temperatures. Commercial in Confidence BRE Global Ltd 2016 Page 11 of 19

13 5.4 Layer 5 Cavity (proposal 1 only) The cavity in both of the tested systems incorporated 15mm-deep timber battens with either Tenmat FF102/15 or AIM VRB Lite intumescent cavity barriers. The proposal is that the cavity depth may be increased, it may be formed using aluminium or steel brackets or battens and/or it may be filled with insulation. Increasing the depth of the cavity will, if anything, improve the overall performance of the system. The temperatures within the cavity will be lower and the temperature of the sheathing board on the internal face of the cavity will therefore also be lower. Using aluminium or steel brackets or battens to create the cavity will have no effect on the fire performance as both products are non-combustible. The maximum temperatures measured within the sheathing board on the outer face of the cavity suggest that the temperatures within the cavity are unlikely to be much greater than 100 C in the worst case when using the minimum thickness of insulation. This temperature is well below that required to ignite most flammable insulation materials. It is therefore reasonable to assume that this cavity could be filled with any insulation material that will not melt at this temperature, e.g. mineral wool, stone or glass, polyurethane insulation or phenolic insulation. 5.5 Layer 4 Inner sheathing board (proposal 1 only) The tested systems each incorporated cement particle sheathing board. Any alternative product is considered suitable from a fire viewpoint as the temperatures at this location will be well below that required to ignite even flammable products. Therefore we consider calcium silicate board, exterior grade plywood or Oriented Strand Board (OSB) all to be acceptable alternatives, providing the minimum thickness is not less than 9mm. 5.6 Layer 3 Structural framing systems (SFS) Proposal 1 (with cavity) The systems were each tested with a 150mm-deep SFS insulated with 140mm-thick stone mineral wool insulation. Again, the temperatures at this location in a BS test will be very low and we therefore consider that the SFS can be reduced in depth to 75mm without increasing the likelihood of burn through. Increasing the depth to 200mm is also considered acceptable. As the temperatures at this location would barely be above ambient during the first 15 minutes of a BS test, any insulation material is considered to be suitable, e.g. stone or glass mineral wool, polyurethane insulation, phenolic insulation, expanded polystyrene insulation, etc Proposal 2 (without cavity) With proposal 2 the maximum temperatures measured within the outer layer of sheathing board in the tests suggest that the temperatures within the SFS are likely to be slightly higher but still not much greater than 100 C in the worst case when using the minimum thickness of insulation. We therefore consider that a reduction in the depth of the SFS to 75mm will not increase the likelihood of burn through. Increasing the depth to 200mm is also acceptable as this will have a beneficial effect on the fire performance. The expected temperature within the SFS is well below that required to ignite most flammable insulation materials. It is therefore reasonable to assume that the SFS frame could be filled with any insulation material that will not melt at this temperature, e.g. mineral wool, stone or glass, polyurethane insulation or phenolic insulation. Commercial in Confidence BRE Global Ltd 2016 Page 12 of 19

14 5.7 Layers 1 and 2 Internal plasterboard lining The plasterboard forming the internal lining can be in a single layer with a minimum thickness of 9.5mm without affecting the fire performance in a BS test as break through is very unlikely due to the low temperatures within the SFS framing with either proposal 1 or proposal 2. Commercial in Confidence BRE Global Ltd 2016 Page 13 of 19

15 6 Conclusion Therefore it is our opinion that the Gebrik Insulating Brick Cladding System tested in BRE reports nos Issue: 1 and P Issue: 2, incorporating the variations described in section 4, would satisfy the performance criteria of BR 135, Third Edition, if tested in accordance with BS :2015. Commercial in Confidence BRE Global Ltd 2016 Page 14 of 19

16 7 Figures Figure 1 Horizontal section through typical system with cavity Commercial in Confidence BRE Global Ltd 2016 Page 15 of 19

17 Figure 2 Vertical section through typical system with cavity Commercial in Confidence BRE Global Ltd 2016 Page 16 of 19

18 Figure 3 Horizontal section through typical system without cavity Commercial in Confidence BRE Global Ltd 2016 Page 17 of 19

19 Figure 4 Vertical section through typical system without cavity Commercial in Confidence BRE Global Ltd 2016 Page 18 of 19

20 8 Validity of the assessment 8.1 Declaration by applicant We the undersigned confirm that we have read and complied with the obligations placed on us by the PFPF Guide to Undertaking Assessments in Lieu of Fire Tests. We confirm that the component or element of structure, which is the subject of this assessment, has not to our knowledge been subjected to a fire test to the Standard against which this assessment is being made. We agree to withdraw this assessment from circulation should the component or element of structure be the subject of a fire test to the Standard against which this assessment is being made. We are not aware of any information that could adversely affect the conclusions of this assessment. If we subsequently become aware of any such information we agree to cease using the assessment and ask BRE Global to withdraw the assessment. Signed: For and on behalf of: 8.2 BRE Global declaration This assessment is issued on the basis of test data and information to hand at the time of issue. If contradictory evidence becomes available to BRE Global the assessment will be unconditionally withdrawn and the applicant will be notified in writing. Similarly the assessment is invalidated if the assessed construction is subsequently tested since actual test data is deemed to take precedence over an expressed opinion. The assessment is valid for a period of five years after which it should be returned for review to consider any additional data which has become available or any changes in the fire test procedures. Any changes in the specification of the product will invalidate this assessment. This assessment has been carried out in accordance with Fire Test Study Group Resolution No. 82. It relates to the fire performance of the product and does not cover aspects of quality, durability, maintenance nor service requirements. This assessment relates only to the specimen(s) assessed and does not by itself imply that the product is approved under any Loss Prevention Certification Board approval or certification scheme or any other endorsements, approval or certification scheme. Next review date: 13 April 2021 Commercial in Confidence BRE Global Ltd 2016 Report Ends Page 19 of 19