Technical Schedule ISSUE STATUS AND AMENDMENTS 3 FOREWARD 5 1. SCOPE 5 2. REFERENCES 5

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1 TECHNICAL SCHEDULE TS15 INTUMESCENT COATINGS USED TO PROVIDE FIRE PROTECTION TO STRUCTURAL STEELWORK Page 1 of 17 This document is the exclusive property of. It shall

2 CONTENTS ISSUE STATUS AND AMENDMENTS 3 FOREWARD 5 1. SCOPE 5 2. REFERENCES 5 3. DEFINITIONS 5 4. GENERAL 6 5. TESTING 7 6. PROCEDURES 7 7. APPRAISAL OF PERFORMANCE APPRAISAL REPORT 12 ANNEX A Testing Procedures 13 ANNEX B Appraisal Procedures 15 ANNEX C Participating Organisations 17 Page 2 of 17 This document is the exclusive property of. It shall

3 ISSUE STATUS AND AMENDMENT i. This is a controlled copy of the. Scheme members to which it has been issued will be provided with details of any changes in accordance with the amendment procedure below. ii. iii. iv. From here on in, references to will be shown as. Each page of the document is identified by a page number, issue number and date. Where an amendment is made, the revised page will bear a new issue number and date of amendment. Where an amendment requires an extra page to be inserted, this is numbered with the number of the preceding page but with the addition of a letter suffix, e.g. 10A will be inserted between pages 10 and 11 and 10B will follow 10A. The new pages are dated in the normal way. v. Any amendment to this document will be identified on the Amendment Page, which will be re-issued to holders of controlled copies with the amended sections/pages. Revised pages shall be inserted in place of existing pages or between existing pages and superseded pages shall be discarded. Where a significant number of amendments are made to this document the entire document will be re-issued under a new issue number. In such cases holders of the document shall destroy the previous issue. vi. vii. The Amendment Page and the relevant revised pages will be produced by Warrington Certification following agreement with the Sector Liaison Group, and issued to the holders of each controlled copy of the document, together with an acknowledgment slip (document transmittal) which shall be signed and returned to to confirm that the document has been amended. It shall be the responsibility of the nominated representative of the organisation to ensure that the document is maintained in an up to date condition at all times. To ensure that a permanent record is available of all amendments, Warrington Certification maintains a file of all superseded pages which are marked with the date of withdrawal. The record is held on file indefinitely in order to allow to determine the past requirements of the scheme at any time. Page 3 of 17 This document is the exclusive property of. It shall

4 AMENDMENT PAGE To ensure that each controlled copy of this contains a complete record of amendments, the Amendment Page is updated and issued with each set of revised/new pages of the document. Details of the procedures for amending this document are given in section 1 of this document. Amendment Discard Insert No Date *Sections Changed Page(s) Issue no Page(s) Issue no All- Updated to new format, also to include references to BS EN ISO/IEC and ISO Management Council renamed to Impartiality Committee All 26 th Jan All Name change from WCL to Exova (UK) Limited trading as All 2 All 3 Page 4 of 17 This document is the exclusive property of. It shall

5 TECHNICAL SCHEDULE (TS 15) INTUMESCENT COATINGS USED TO PROVIDE FIRE PROTECTION TO STRUCTURAL STEELWORK FOREWORD This document has been prepared and agreed in accordance with the requirements of BS SCOPE This relates to the CERTIFIRE system for the appraisal of the fire performance of intumescent coatings used to provide fire protection to structural steel. The detailed scope of a systems appraisal is given in the Appendices associated with the Certificate of Registration. 2. REFERENCES EN Standards are published by National Standards body and may include National Annexes. For CERTIFIRE purposes the definitive version of any EN standard is that published by BSi and prefixed BS EN. References contained in TS00 may also be relevant BS 449: Part 2 BS 476: Part 8 BS 476: Part 20 BS 476: Part 21 Specification for the use of structural steel in building. Metric units Fire tests on building materials and structures. Test methods and criteria for the fire resistance of elements of building construction Fire tests on building materials and structures Fire tests on building materials and structures. Methods for determination of the fire resistance of loadbearing elements of construction 3. DEFINITIONS Page 5 of 17 This document is the exclusive property of. It shall

6 4. GENERAL These procedures are based on the best available knowledge at the time of writing and are considered to provide a reliable means of evaluating the performance of intumescent fire protection materials in terms of BS 476: Part 21. However, many factors can affect the performance of intumescent coatings under test conditions and some minor variation between the performance in tests and that predicted by these appraisal methods could occur. Appraisals will be based on information derived from tests on loaded beams and/or columns carried out in accordance with BS 476: Part 21 and additional information derived from tests on unloaded steel sections subjected to the heating conditions specified in BS 476: Part 20. Completion of a single loaded test would permit an appraisal to be carried out, but this would be restricted to fire resistance periods less than the time for which the test specimen complied with the stability criterion, the actual thickness tested and the steel shape and orientation tested. Restrictions on the Hp/A range would also be necessary. The scope of a products certification need not cover all the shapes and orientations detailed in this. Where a product is only intended to be used on beams or columns an appraisal can be carried out but at least two loaded tests would be required to investigate both maximum and minimum thickness for the required fire resistance periods. In addition, some unloaded sections would be required. The programme of tests need not be restricted to one steelwork shape, but additional loaded tests may then be necessary. Similarly an appraisal need not cover all the steelwork shapes. Certification can be restricted to one or more shapes alone, e.g. I sections only, but at least 3 loaded tests plus unloaded sections would be required to cover both orientations and a range of thickness. Page 6 of 17 This document is the exclusive property of. It shall

7 5. TESTING The appraisals will be primarily based on test information from NAMAS approved laboratories. Appropriate data from other independently validated sources may be used to supplement the appraisal but will not be used as the main basis of evaluation. Where BS 476: Part 21 does not provide full details of test procedures, resolutions of the Fire Test Study Group (UK) and the scheme described in Note 1 Testing Procedures, should be followed. 6. PROCEDURES The potential fissuring cracking or detachment of a fire protection material may not only become apparent during full scale fire resistance tests. The loaded tests are therefore designed to provide information regarding the physical/mechanical performance of fire protection under the following conditions: 1. Vertical and horizontal orientations 2. Maximum and minimum protection thickness 3. Maximum and minimum fire resistance period under consideration To demonstrate the retention of the fire protection material, loaded beam tests should be continued until structural failure imminent. Page 7 of 17 This document is the exclusive property of. It shall

8 There is no fixed programme of test specified, as each fire protection material will have a different performance and target market. However, to maintain a consistency of approach and to enable the test laboratories to maintain a stock of appropriate test specimens, the following steel sections are suggested for the development of a test programme: I Sections 305 x 102mm x 25Kg/m 254 x 146mm x 31Kg/m 356 x 171mm x 67kg/m 203 x 203mm x 52Kg/m 254 x 254mm x 89Kg/m 254 x 254mm x 132Kg/m 406 x 178mm x 60Kg/m 305 x 127mm x 42Kg/m 254 x 146mm x 43Kg/m 152 x 152mm x 30Kg/m 610 x 305mm x 238Kg/m Page 8 of 17 This document is the exclusive property of. It shall

9 Rectangular Hollow Sections 80 x 80 x 3.6mm 120 x 60 x 3.6mm 150 x 150 x 5.0mm 200 x 200 x 6.3mm 150 x 100 x 8.0mm 300 x 200 x 8.0mm 140 x 140 x 5.0mm 250 x 250 x 12.5mm 100 x 100 x 5.0mm 300 x 300 x 12.5mm The scope of the appraisal will depend on the nature of tests carried out and the performance of the material in those tests. Page 9 of 17 This document is the exclusive property of. It shall

10 For a system which is used over a range of thickness and steel shapes the following tests are considered appropriate. Thickness refers to dry film thickness (see Note 2). I Sections 406 x 178mm x 60Kg/m Beam Maximum thickness 203 x 203mm x 52Kg/m Column Maximum thickness Rectangular Hollow Sections 200 x 200 x 6.3mm Column Maximum thickness 300 x 200 x 6.3mm Beam Maximum thickness Plus any of the above at minimum thickness dependent on the performance of the coating. If reinforcement is used over part of the thickness range additional loaded tests will be required. Page 10 of 17 This document is the exclusive property of. It shall

11 7. APPRAISAL OF PERFORMANCE The aspects considered in the appraisal of test data are: Section factor (Hp/A) Shape of section Size of section Fire resistance period Critical temperature Orientation of section Thickness and density applied protection Surface preparation of steel Reinforcement (if any) Primer compatibility Manner of application (bush/spray) Effects of overcoating Number of coats Page 11 of 17 This document is the exclusive property of. It shall

12 8. APPRAISAL REPORT Following the completion of the appropriate test and appraisal package a fully documented report will be prepared. The appraisal report will fully detail the scope of approval, basis of the appraisal and justification for any variations from the procedure detailed in this. All test data used in the preparation of the appraisal should be fully referenced by the test number and type of test (beam/column, loaded/unloaded, full scale/small scale, etc.) The format of the report will provide the following details: 1. Fire Protection Material - Brief description of generic types 2. Test Specimens - No. of specimens and sizes used in the analysis 3. Limits of Acceptability - Details of any constraints 4. Predictive Analyses - Summary of test results Summary of analysis data 5. Predicted thickness for various section factors 6. Data Sheet 7. The test reports used for the appraisal should be appended to the assessment report. 8. Physical performance and retention material. Page 12 of 17 This document is the exclusive property of. It shall

13 ANNEX A TESTING PROCEDURES These procedures are additional to or highlight those specified in BS 476: Part 8 and Part The materials and standards of workmanship of the test specimens shall be representative of good site practice. 2. Test specimens shall be conditioned in such a manner that they correspond as closely as possible, in temperature, solvent content and state of cure to the expected state of a similar element in service. 3. Loaded specimens should comply with the minimum dimensional requirements of BS 476: Part 21 and non-loaded specimens used to provide temperature data should have a length of at least 1 meter. 4. To provide maximum information it is recommended that tests should be continued until all steel sections have reached 800 o C (or other maximum appraisal temperature required by the applicant) or until the insulation system has suffered a significant detachment from the steel section. 5. If loss of load bearing capacity of a loaded specimen occurs (or is imminent) the load should be removed and the test continued until the conditions given in Note 1(4) are achieved 6. The average steel temperature shall be measured at intervals not exceeding 2 minutes. The average steel temperature are defined as follows: i) I section beams with three sided exposure: (average temperature of lower flange + average web temperature) /2. ii) iii) iv) I section columns with four sided exposure: (average temperature of both flanges + average web) /2. RHS beams with three sided exposure: (average temperature of the three exposed faces). RHS/CHS columns with four sided exposure; (average temperature of thermocouples on all faces of column). 7. The load applied to loaded specimens shall not be less than the maximum design load specified in BS 449: Part 2). Page 13 of 17 This document is the exclusive property of. It shall

14 8. Mineral or ceramic fibre insulation should be provided between the top flange of all unloaded beams and the concrete cover slab. 9. Loaded beams shall be tested with their ends fixed (i.e. restrained in direction and against rotation). In certain cases it may not be practical to comply with all the above requirements. In such cases all variations should be agreed with Certifire and the reasons for and details of the variation will be included in the appraisal report. Page 14 of 17 This document is the exclusive property of. It shall

15 ANNEX B APPRAISAL PROCEDURES 1. Appraisal will only be made regarding the performance of horizontal elements if a loaded beam test in accordance with BS 476: Part 21 has been successfully* completed. 2. Appraisals will only be made regarding the performance of vertical elements if a loaded column test in accordance with BS 476: Part 21 has been successfully* completed. 3. If during the period loaded test stability failure of the specimen occurs before the appropriate fire resistance period is achieved (i.e. 1 hour 55 minutes rather than 2 hours) the information may be used in the appraisal provided that no significant detachment of the insulation system occurs within the appropriate fire resistance time and the requirements of Note 2 (1) and/or (2) above have been fulfilled on a different section size and shape. However, the thickness of fire protection material and fire resistance time covered by the appraisal will not be extrapolated by more than 10% of the maximum thickness or time tested in accordance with BS 476: Part The total average dry film thickness (dft) will be used as a basis for appraisals. The assessment should take account of the individuals dft s of primer, intumescent and top coats. For test purposes the coating should be applied such that the standard of deviation of dft about the mean is not more than 15%. Assuming that the readings are normally distributed this implies that: a) 68% of readings are within 15% of mean b) 95% of readings are within 30% of mean c) 99% of readings are within 45% of mean If the above criteria are not met the thickness distribution will be considered in detail by CERTIFIRE and where appropriate safety factors introduced into the assessment to take account of the variability. 5. Appraisals only apply to the specific formulations tested. 6. The acceptable range of the thickness usage is related to the maximum and minimum thickness tests in loaded sections. The extrapolation of maximum and minimum thickness will normally only be acceptable by up to 10% of the maximum thickness tested. Page 15 of 17 This document is the exclusive property of. It shall

16 7. For appraisal purposes steel section shapes will be divided into the following groups: I sections (or other section shape providing a re-entrant profile) a) Horizontal b) Vertical Square/rectangular section a) Horizontal b) Vertical 8. Each of the shape groups detailed in Note - 4 (7) is treated separately for the purpose of appraisals. Assessments for circular sections may normally be based on tests on square sections. Alternatively tests on circular sections may be evaluated separately. 9. To establish the performance of a material on deep web sections a deep web unloaded section should be included in the test package. Where this information is not available the following constraints shall apply, based on the size of loaded beam tested. Beam size tested Maximum web/flange size for appraisal purposes 305 x 127 x mm/210mm 406 x 178 x mm/305mm 10. When considering the performance of elements fully loaded in accordance with BS 449 the following criteria should apply. The assessment shall be carried out separately for beams and columns. The temperature used for the assessment shall be the lowest temperature at failure of the appropriate beam or column when tested in accordance with BS 476: Part 21 except that this temperature should not exceed 550 o C except for beams with 3 sided exposure and supporting concrete slabs when the temperature should not exceed 620 o C. 11. The use of the regression analysis which has been successfully used for passive materials is usually not applicable to intumescent coatings. Where the regression technique is not applicable the analysis of data will be carried out on the basis of graphical interpolation between data points using a plot of A/Hp versus fire resistance. 12. Situations may arise where certain of the above principles are not appropriate to a particular appraisal. In such circumstances the reason for the variation and the justification for the alternative must be clearly detailed in the appraisal report. * In this context successfully means that the specimen tested has achieved the specific standard of fire resistance (in terms of BS 476: Part 21) under consideration (i.e. ½ hour or 1 hour). Page 16 of 17 This document is the exclusive property of. It shall

17 ANNEX C PARTICIPATING ORGANISATIONS BODIES AUTHORISED TO OPERATE CERTIFICATION TO THE PROVISIONS OF THIS SCHEDULE THIS SCHEDULE IS RATIFIED BY MEMBERS OF THE WARRINGTON CERTIFICATION IMPARTIALITY COMMITTEE Association for Specialist Fire Protection (ASFP) British Automatic Fire Sprinkler Association (BAFSA) British Retail Consortium (BRC) British Woodworking Federation (BWF) Chief Fire Officers Association (CFOA) Construction Products Association (CPA) Department of Communities and Local Government (DCLG) Door and Hardware Federation (DHF) Fire Protection Association (FPA) Glass and Glazing Federation (GGF) Guild of Architectural Ironmongers (GAI) Institute of Fire Prevention Officers (IFPO) Institute of Fire Safety Manager (IFSM) London Underground Limited (LUL) Royal Institute of Chartered Surveyors (RICS) RISC Authority Secured By Design (SBD) Local Authority Building Control (LABC) Exova Warringtonfire (EWF) Users of documents are reminded that copyright exists in all CERTIFIRE publications. No part of this publication may be reproduced in any form without prior permission in writing from Warrington Certification. Permission to copy this document for internal use and promotional purposes only is automatically granted to companies holding CERTIFIRE certification. Such copies are uncontrolled and this status should be identified on each copy Copyright Holmesfield Road, Warrington, Cheshire, WA1 2DS Reg. Office: Exova (UK) Limited, Lochend Industrial Estate, Newbridge, Midlothian EH28 8PL United Kingdom. Tel: +44 (0) EWCL@exova.com Website: Page 17 of 17 This document is the exclusive property of. It shall