WFCi Report # Conducted For: Supress Products LLC. 5/8 Supress Sound-Engineered Drywall SED58410C; U305 Design

Transcription

1 Fire Performance Evaluation of a Load- Bearing 2 x 4 Wood Stud Wall Construction in Accordance With ASTM E119-05: Standard Test Methods for Fire Tests of Building Construction and Materials 5/8 Supress Sound-Engineered Drywall SED58410C; U305 Design WFCi Report #08043 Conducted For: Supress Products LLC Conducted On: June 13 and 24, 2008 Report Issued On: July 10, 2008

2 TABLE OF CONTENTS TABLE OF CONTENTS...2 INTRODUCTION...3 SUMMARY OF TEST METHOD...4 DESCRIPTION OF LABORATORY TEST FACILITY...5 SAMPLE DESCRIPTION...6 FIGURE 1: STUD AND WALLBOARD LAYOUT DIAGRAM...7 WEIGHT AND LOAD INFORMATION...8 LOAD CALCULATION...8 THERMOCOUPLE LAYOUT...9 Finish Rating Thermocouples...9 Unexposed Surface...9 FIGURE 2: UNEXPOSED THERMOCOUPLE LOCATIONS (RIGHT SIDE = NORTH)...10 TEST DATA...11 TEST OBSERVATIONS...11 DEFLECTION MEASUREMENTS...12 FURNACE TEMPERATURES...12 MEMBRANE RATING THERMOCOUPLE TEMPERATURES...13 UNEXPOSED SIDE THERMOCOUPLE DATA...16 HOSE STREAM RETEST...17 HOSE STREAM RETEST RESULTS...18 TEST RESULTS AND CONCLUSION...18 SIGNATURES...19 APPENDIX A: GRAPHS AND TABULATED DATA...20 FURNACE TEMPERATURE DATA...21 UNEXPOSED FACE THERMOCOUPLE DATA...23 HYDRAULIC LOAD PRESSURE...25 FURNACE PRESSURE AT TOP OF WALL...26 AXIAL DISPLACEMENT...27 APPENDIX B: PHOTOGRAPHS...28 Western Fire Center, Inc. Page 2 of 32

3 INTRODUCTION This report documents the successful fire resistance and hose stream testing of a one-hour load-bearing 10 high X 10 wide, 2 X 4 wood stud wall construction faced on both sides with 5/8 Supress Sound-Engineered Drywall SED58410C performed by Western Fire Center, Inc. (WFCi) for: Supress Products, LLC Howard Stacy and Mike White of WFCi supervised construction of the test wall by WFCi staff, and conducted the test with assistance from technicians Wayne Beres and Nick Martin (WFCi). The purpose of this test was to determine the fire-resistance rating of the wood stud/gwb wall assembly when subjected to ASTM E119 test conditions for a minimum endurance period of one hour. Western Fire Center, Inc. Page 3 of 32

4 SUMMARY OF TEST METHOD This is a vertical fire test employing the fire endurance conditions described in ASTM E , Fire Tests of Building Construction and Materials. The test conditions are also closely described by testing standards UBC 7-1, 1997, UL 263, and NFPA 251. A vertical exposure furnace (described in the following section) was used to subject the sample to a standard timetemperature curve as specified in the referenced test procedures. -The neutral pressure plane was located near the top of the wall assembly. -For this fire endurance evaluation, the test was to be performed for a fire resistance period of one hour or until failure of the assembly occurred. Western Fire Center, Inc. Page 4 of 32

5 DESCRIPTION OF LABORATORY TEST FACILITY The furnace used in the test is a large-scale fire burning apparatus, fueled by natural gas (pictured below). The furnace is mounted to the floor, with the back side close to the west wall, at the south end of the laboratory facility. Inside the laboratory to the north of the furnace is a large area for specimen construction and curing. Ambient temperature in the laboratory is controlled by natural gas radiant heaters at the ceiling level. The wall section is mounted in a vertical orientation into a steel frame specimen holder. The specimen holder is then rolled up to the furnace and secured by four pneumatic rams to the furnace opening. Combustion air and natural gas are supplied to burners through a series of pipes and valves. Internal furnace pressure is controlled by a series of dampers in the exhaust outlets. Temperature measurements are recorded by calibrated data acquisition units which pass the readings to a computer for graphical display and storage. A large roll up door is in the wall opposite the furnace area and allows for the samples to be moved approximately 40 on tracks outdoors to the area designated for hose stream testing. Western Fire Center, Inc. Page 5 of 32

6 SAMPLE DESCRIPTION The construction of the 10 tall x 10 wide single leaf fire test wall sample was based upon specifications detailed in UL Design No. U305. The assembly consisted of select structural grade, nominal 2x4-in. Douglas fir wood studs spaced 16-in. O.C. (12 O.C. between first two and last two studs) with two top plates and one bottom plate. All stud and plate pieces were attached with 16d common nails. The external faces of the wall were each covered with one layer of 5/8 Supress Sound-Engineered Drywall SED58410C mounted vertically on both sides (parallel to the supporting elements). The GWB joints on each side were covered with paper tape and gypsum joint compound in the standard manner. The screw heads were also covered with joint compound. Wood Framing: Nominal 2 in. by 4 in. select structural Douglas fir studs bearing the grade stamp of a nationally recognized grading agency, having an average moisture content of approximately 11% percent prior to application of the Supress drywall on the test wall. The average weight of the wood studs was 11.8 lbs, ranging from 10 to 14 lbs. Horizontal blocking was placed across the center of the wall at approximately 60 height. Fasteners: No. 6 x 1-5/8 type W drywall screws spaced at 8 on center on the perimeter and 12 oc in the field; applied a minimum of 3/8 from the vertical edges of the GWB. Supress Sound-Engineered Drywall SED58410C: Single layer 5/8 Supress drywall, having an average unit weight of 2.76 lbs/sq.ft (2763 lbs/msf), and an average caliper of in. (as measured by micrometer). As described by the client, the SED58410C drywall product consists of a gypsum and mineral board laminated through a Supress proprietary process. Western Fire Center, Inc. Page 6 of 32

7 The drywall was attached to the supporting elements with the side with the gypsum wallboard laminate facing out. Both sides of the wall were comprised of three panels of drywall: one 4 x10 sheet, one 44 x10 sheet and one 28 x10 sheet mounted with vertical seams centered over the vertical wood stud structural elements. The mounting of the wallboard was such that the placement of the 28 and 44 wide sheets were on alternate sides of the assembly on the exposed and unexposed sides. Tape and joint compound was applied to fastener heads and joints on the faces of the exposed and unexposed sides in the standard manner. Figure 1: Stud and Wallboard Layout Diagram Western Fire Center, Inc. Page 7 of 32

8 Weight and Load Information A superimposed axial load of 2,004 pounds per stud (1,804 PLF) was applied to the assembly throughout the test. A graph in Appendix A depicts the load throughout the test in terms of the pounds per square inch (PSI) setting of WFCi s hydraulic load application system. For this calibrated load application, the system was maintained at 358 PSI throughout the test. This loading constituted the maximum fire-rated design stress condition (78% of the maximum design load) for this construction as referenced by the National Design Specifications for Wood Construction (1982 and later editions), and the Gypsum Association Fire Resistance Design Manual, 18 th Ed., Page 7. The load-bearing test was performed by fastening the test wall assembly to the test frame at top and bottom, while leaving the vertical sides unrestrained. The test wall was placed between the top and bottom beams of the load frame with five hydraulic actuators pressing upwards on the moveable bottom beam until the desired load was attained. This axial live load was applied to the test wall approximately 30 minutes prior to the test. Load Calculation Hydrauli c ram pressure, P R (lbs/in 2 ) Length of sill plate, L P (inches) Width of sill plate, W P (inches) Number of studs, N S (-) Weight of test sample incl. plates, gyp., etc W S (lbs) Effective area of each hydrauli c ram A R (in 2 ) Number of hydrauli c rams used, N R (-) Total effective area of the hydrauli c rams, A T (in 2 ) Weight of moveabl e beam, W B (lbs) Western Fire Center, Inc. Page 8 of 32

9 Total upward forces, U F (lbs force) Total downwar d forces, D F (lbs force) Total load on wall system, L T (lbs force) Load per linear foot of wall, L F (lbs/ft) Load per stud, L S (lbs/stud Load on sill plate L P (lbs/in 2 ) Thermocouple Layout A total of 14 thermocouples were used to measure temperature data during this test: 5 on the back face of the exposed sheathing attached over the studs at the four ¼-points and center-point location (finish/membrane rating) and 9 on the unexposed surface. Finish Rating Thermocouples Thermocouples 1 through 5 were placed at the sample center and quarterpoints beneath the exposed layer of wallboard to obtain finish rating data. Unexposed Surface Thermocouples 6-14 were placed in an evenly-spaced 3X3 grid on the unexposed surface. The center column and row were approximately centered vertically and horizontally across the surface, respectively. Each thermocouple was placed within approximately 1-1/2 in. from the vertical supporting elements. Western Fire Center, Inc. Page 9 of 32

10 Figure 2: Unexposed Thermocouple Locations (right side = North) Western Fire Center, Inc. Page 10 of 32

11 TEST DATA Test Observations Test Date: Specimen Tested: 10 X10 Wood Stud Wall with Single Layer 5/8 SED58410C drywall Furnace: Vertical Exposure Furnace Cameras: 1 digital still camera and 1 video camera Wood Stud Moisture Content: ~11% Ambient Conditions: Lab room Temp: 16 C / 48% RH Test Time (h:mm:ss) Event 0:00:00 Start Test 0:01:03 Ignition of exposed gypsum paper 0:02:00 Flames out 0:03:00 Light cracking of GWB vertical ht. of exposed 0:20:00 GWB is delaminating, cracking and lifting at various places 0:22:00 Flames emitting at spots where GWB has delaminated 0:22:44 Finish rating attained 0:26:00 GWB layer falling off into furnace in large pieces, exposing mag board layer 0:28:00 Mag board bulging between fasteners, joints remain tight 0:30:00 Gaps at edges to ¼ ; exposed surface of board has smooth and even appearance 0:31:00 Light flaming begins at joints; some tearing at fasteners near jt. edges 0:36:00 Bulging along joints creating 1 openings, no flaming noted 0:39:00 Light flaming at midheight of N joint 0:43:00 A 4 diameter opening appears lower S quarter point, flaming increasing along vertical joints, bulging of board more pronounced 0:53:00 Additional small openings in exp d face with flame emission, flames along jts increasing 1:00:00 Pass One Hour Fire Resistance. Test terminated at request of sponsor for performance of hose stream test. Test wall subjected to hose stream test within 2.5 minutes: failure occurs at approximately 45 seconds- wall fails to carry load due to stud fracture. See hose stream retest results. Western Fire Center, Inc. Page 11 of 32

12 Deflection Measurements During the test, horizontal deflection measurements were taken every five minutes at five locations on the unexposed sample surface to monitor horizontal movement and/or buckling of the sample. Vertical (axial) deflection was recorded by two linear displacement transducers placed at each end of the load beam and recorded continuously. Vertical deflection is reported graphically in Appendix A. Horizontal Deflection Measurements Locations: 1=upper south ¼ pt.; 2=upper north ¼ pt.; 3=center; 4=lower south ¼ pt.; 5= lower north ¼ pt. Time Measurement (inches) Loc #1 Loc #2 Loc #3 Loc #4 Loc #5 0:00: :05: :10: :15: ¼ 0 0 0:20: ¼ 0 0 0:25: ¼ 0 0 0:30: ¼ 0 0 0:35: ¼ 0 0 0:40: ¼ 0 0 0:45: ½ 0 0 0:50: ½ 0 0 0:55:00 ¼ ¼ 1 ½ ¼ 1:00:00 1 1/2 1 3/4 1 1/2 Notes: Maximum deflection of 1.75 inches at center of wall at test termination. Furnace Temperatures The area under the actual time-temperature curve was determined to be within 1% of standard. The required area under the standard timetemperature curve is 45,740 deg. C-minutes, and the area under the actual curve was 45,465 deg. C-minutes. Western Fire Center, Inc. Page 12 of 32

13 Furnace temperatures are tabulated in Appendix A. Furnace Temperature Degrees C Act. T-t Std. T-t Time (min) Membrane Rating Thermocouple Temperatures Thermocouples 1-5 were placed on the exposed (furnace) side of the wood studs beneath the base layer of GWB to obtain finish rating data during the test. The initial average temperature of the wood studs was 15.6 C; therefore, based on the average temperature rise of 139 C and a maximum individual temperature rise of 181 C above the initial temperature, the average limiting temperature was C and the individual limiting temperature was C. Western Fire Center, Inc. Page 13 of 32

14 Limiting Temperature Criteria ( C) Average: 139 C C Individual: 181 C C Temperature Limits Reached (mm:ss): Average: 22:45 Individual: N/A Finish Rating Tcs FR1 FR2 Degrees C Finish Rating = 22:45 (average) FR3 FR4 FR5 Avg. FR tcs Avg. FR tcs Time (min) Western Fire Center, Inc. Page 14 of 32

15 Finish (Membrane Protection) Rating Data Time TC1 TC2 TC3 TC4 TC5 Average (mm:ss) 00:00: :01: :02: :03: :04: :05: :06: :07: :08: :09: :10: :11: :12: :13: :14: :15: :16: :17: :18: :19: :20: :21: :22: :23: Western Fire Center, Inc. Page 15 of 32

16 Unexposed Side Thermocouple Data Limiting Temperature Criteria ( C) Average: 139 C C Individual: 181 C C Temperature Limits Reached (mm:ss): Average: N/A Individual: N/A (TC No. N/A) Unexposed Side Temperatures UE6 UE7 Degrees C Test Termination UE8 UE9 UE10 UE11 UE12 UE13 UE14 40 Avg. Unexp Tcs Time (min) Western Fire Center, Inc. Page 16 of 32

17 HOSE STREAM RETEST The hose stream retest was conducted on a duplicate wall construction on June 24, 2008 in accordance with the standard. Immediately following the 30 minute fire exposure portion of the hose stream retest, the test assembly was removed from the furnace and moved into position for the hose stream test. The assembly was subjected to the impact, cooling and eroding action of a hose stream applied to the exposed surface of the test assembly. The hose steam test was conducted within 2.5 minutes after the fire exposure was terminated. HS Retest Furn. Temp. Data, Degrees C Act. Curve Std. Curve Time (min) Based on a 1 hour exposure time, the standard requires the test assembly to be subjected to the action of a 30 psi hose stream applied for a duration of 1 minute. The hose stream was applied with a 1-1/8 in. diameter nozzle at a Western Fire Center, Inc. Page 17 of 32

18 perpendicular distance of 20 ft. from the center of the test assembly. The hose stream was applied to the 100 ft² sample and traversed the wall assembly. Hose Stream Retest Results No through projection of water was observed beyond the unexposed surface of the wall assembly after 1 minute. The appearance of the exposed and unexposed surfaces of the wall assembly before and after the fire exposure and hose stream test are shown in Appendix B. TEST RESULTS AND CONCLUSION Charts illustrating data collected from the test are included in Appendix A. Photographs from the test are included in Appendix B. Finish (Membrane Protection) Rating: 0:22:45 The wall assembly supported the applied load for 60 minutes. The wall assembly did not allow passage of flame or gases hot enough to ignite cotton waste at any time during the testing. Temperatures on the unexposed face remained within the allowed single-point temperature rise of 181 C (325 F) above the starting temperature of 15.6 C throughout the test. The average temperature rise for the unexposed face thermocouples remained within the allowable limit of 139 C (250 F) above the starting temperature of 15.6 C throughout the test. A duplicate wall construction successfully met the conditions of acceptance for the hose stream test requirement. The wall assembly met the ASTM E119 conditions of acceptance for a load-bearing 60-minute classification with hose stream, carrying the applied load without passage of flame or heat enough to ignite cotton waste and staying within the temperature rise criteria throughout the test. Western Fire Center, Inc. Page 18 of 32

19 SIGNATURES Test Performed by: Mike White Laboratory Director Prepared and Approved by, Howard Stacy Director, Testing Services WESTERN FIRE CENTER INC. AUTHORIZES THE CLIENT NAMED HEREIN TO REPRODUCE THIS REPORT ONLY IF REPRODUCED IN ITS ENTIRETY. The test specimen identification is as provided by the client and WFCi accepts no responsibilities for any inaccuracies therein. WFCi did not select the specimen and has not verified the composition, manufacturing techniques or quality assurance procedures. Western Fire Center, Inc. Page 19 of 32

20 APPENDIX A: Graphs and Tabulated Data Western Fire Center, Inc. Page 20 of 32

21 Test Time Furnace Temperature Data Furnace Temperatures (min) TC1 TC2 TC3 TC4 TC5 TC6 TC7 TC8 TC9 ( C) Avg. Frn. Temp Western Fire Center, Inc. Page 21 of 32

22 Western Fire Center, Inc. Page 22 of 32

23 Unexposed Face Thermocouple Data Time UE6 UE7 UE8 UE9 UE10 UE11 UE12 UE13 UE14 Avg.UE tcs (min) ( C) ( C) ( C) ( C) ( C) ( C) ( C) ( C) ( C) ( C) Western Fire Center, Inc. Page 23 of 32

24 Western Fire Center, Inc. Page 24 of 32

25 Hydraulic Load Pressure Load Pressure Load Pressure (PSI) Load Pressure Time (m) Western Fire Center, Inc. Page 25 of 32

26 Furnace Pressure at Top of Wall Furnace Pressure Furnace Pressure (IN H2O) Furnace Pressure Time (m) Western Fire Center, Inc. Page 26 of 32

27 Axial Displacement Axial Displacement Inches LDT1 LDT Test terminated at 60' for hose stream test Time (min) Western Fire Center, Inc. Page 27 of 32

28 APPENDIX B: PHOTOGRAPHS Western Fire Center, Inc. Page 28 of 32

29 Pretest Unexposed side prior to test termination Western Fire Center, Inc. Page 29 of 32

30 IR image of unexposed side at termination Exposed side fire test wall immediately following fire exposure Western Fire Center, Inc. Page 30 of 32

31 Hose Stream test wall prior to test Exposed surface of retest wall after application of hose stream Western Fire Center, Inc. Page 31 of 32

32 Unexposed side of retest wall after hose stream application Western Fire Center, Inc. Page 32 of 32