28408 Lorna Ave. Warren, MI 48092

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1 Phone: Fax: Lorna Ave. Warren, MI 48092

2 COPYRIGHT Firespray International Ltd. All Rights Reserved; Revision 2.0 2

3 The Firespray Flamebar BW11 System is an innovative solution for Commercial Kitchen Grease Duct Ventilation in full compliance with the recent changes to the model codes for Duct segments are constructed from 20-gauge galvanized sheet metal in flanged sections up to 49 x 49 cross section. The duct is then degreased and factory fire sprayed with Flamebar BW11 which is a specially formulated, water based compound which contains selected mineral filters in a lower permeability elastomeric binder to a thickness of approximately 0.04 (1mm) to give a VOC-free finished product. The ductwork is fabricated in flanged sections up to 59 in length and is assembled on site utilizing Flamebar gaskets and sealants. For Grease Duct applications requiring a shaft enclosure or a zero clearance installation, the ductwork can then be wrapped with Unifrax FyreWrap Elite 1.5 or Max 2.0 duct insulation, consisting of two layers applied directly to the duct surface in accordance with Unifrax s installation instructions. Firespray International utilizes a Complete System approach to perform the task of complying with the rigorous testing and application requirements associated with the exhaust ventilation of grease-laden vapors from a commercial cooking facility: Duct segments incorporate a strict fabrication specification including gauge, seams, flanges, reinforcement, access door construction, wall and floor penetration seals, etc. Further, recognizing that the supports are an integral part of the system, and that the tensile strength of steel is significantly reduced under a fire load, the comprehensive specification directly addresses both vertical and horizontal arrangements and the enhanced hardware requirements (anchors, threaded bar, unistrut, etc.). Spray facilities are operated by trained and licensed operators, performing the degreasing and coating application to strict guidelines, in addition to being subject to periodic inspection by Intertek ETL inspectors. Installation of ductwork is performed on site by contractors that receive both training and support by Firespray and its Licensees, in accordance with the Flamebar specification. All installations are inspected by Firespray and/or its Licensees subject to a comprehensive checklist, and issued an Approval Certificate affixed with a Seal of Compliance. The Firespray Flamebar BW11 System is a purpose built system that is uniquely constructed as a fire resistive enclosure for commercial kitchen Grease Ducts. It is a tested and proven performer on a worldwide basis and fully complies with standards UL 1978 and ASTM E-2336, as referenced by the IMC, UMC, and the NFPA. It is an acceptable alternative to a 2-hour fire resistant rated shaft enclosure when used in conjunction with the Unifrax FyreWrap Elite 1.5 or Max 2.0 insulation, thus providing zero clearance to combustibles. 3

4 There are numerous advantages to the Flamebar system that apply to all parties involved, including the Building Owner, the Architect, the Consulting Engineer, General Contractor, Mechanical Contractor, and Installing Contractor: Safety with Single Source Responsibility o The design of all Flamebar BW11 Fire Duct Systems is to a certified standard. o Flamebar BW11 Grease Duct is manufactured and sprayed to standards set by Firespray. o Flamebar BW11 Grease Duct is erected to Firespray installation standards. o All Flamebar BW11 installations meeting specification requirements are issued a Certificate of Conformity. Code Compliance and Testing o Flamebar BW11 Grease Duct complies with ASTM E-2336 and is listed by Intertek ETL Testing Services to provide a 2-hour rating for fire resistive Grease Ducts (as referenced by the IMC, UMC, and NFPA96). o Flamebar BW11 Grease Duct also fully complies with the performance requirements of UL 1978 and is tested by Intertek ETL Testing Services. o Refer to the Testing section below in this document for additional related tests. A Competitive and Proven Solution The Flamebar BW11 Fire Duct system has been used extensively throughout Europe, the Middle East, and the Far East for more than 20 years in a variety of applications and in the United States since The Flamebar BW11Grease Duct is particularly competitive against alternative systems and can yield significant cost savings on an installed basis depending on the project parameters. Rapid Installation The Flamebar BW11 Grease Duct System s relatively light weight and use of conventional flanged sections enables contractors to perform the installation on site at a substantially greater rate than the conventional approach utilizing welded joints on 16-gauge carbon steel. Large Size Capability The Flamebar BW11 Grease Duct is Listed by Intertek ETL for rectangular ductwork in sizes up to 49 x 49, the largest ever tested. Relatively Light Weight The Flamebar BW11 Fire Duct is the lightest fire duct system available. Leakage Testing The construction and sealing of the Flamebar BW11 Fire Duct System allows the ductwork to be tested up to a maximum of 6 wg pressure per SMACNA, if required by the client. Moisture Absorption The Flamebar BW11 Fire Duct system is non-hygroscopic and has been tested in an artificial weatherometer to an equivalent of 60 years of external exposure. Systems installed outdoors, however, require additional protection (refer to Installation Section on page 10). Mold Resistance The Flamebar BW11 Duct System contains antimicrobial biocide and has been evaluated for resistance to fungal attack. It does not support the growth of mold, fungi or bacteria. Easily Cleaned The robust and smooth internal finish of Flamebar BW11 Systems enable easy cleaning of the ductwork and is therefore ideal for Commercial Kitchen Grease Duct installations. 4

5 ASTM E-2336: Fire Resistive Grease Duct Enclosure Systems ASTM E-84 / UL723: Surface Burning Characteristics - Flame Spread Rating - Smoke Developed Rating ASTM E-814: Firestop Test ASTM E-136: Non Combustibility Test Complies, Listed by Intertek ETL Zero clearance to combustibles at all locations on duct wrap s surface Unfaced Blanket Encapsulated Zero <25 Zero <50 Classified by UL: F-Rating = 2 Hrs; T-Rating = 2 Hrs. Refer to section on Through Penetration Fire Seals in the Installation section of this document for more detail Complies ASTM C-518: Durability Test UL 1978: Test Standard for Grease Ducts Complies Complies, Evaluation Report by Intertek ETL confirms that all performance requirements of UL 1978 have been met, including Section 16, (Grease/Lard) Leakage Test ASTM E2336: Fire Resistive Grease Duct Enclosure Systems Flamebar BW11 Grease Duct is a Listed System to ASTM E The Standard evaluates enclosure materials and grease duct enclosure systems using five test methods as outlined below: 1. Non-Combustibility: As defined by ASTM E-136, it demonstrates the enclosure material s ability to resist combustion at a standardized temperature and duration. 2. Fire Resistance: as defined by E-119, it illustrates the ability of the enclosure material to resist the effects of fire when applied in a vertical application; includes a hose stream test. 3. Durability: As defined by ASTM C-518, it simulates the effects of long term exposure of typical in-service conditions on the thermal conductivity of the enclosure materials. 4. Internal Fire: Uses two standardized fire exposures occurring inside the grease duct where first the temperature is raised to 500F and maintained for 4 hours, and then elevated to 2,000 F and maintained for 30 min. In addition to verifying that there are no openings on the surface of the enclosure material and also the absence of flaming, the temperature of the outer surface is measured against set limits for both tests. Passing this test provides the zero clearance to combustibles rating. 5. Fire Engulfment with through penetration fire stop: As defined by ASTM E-119, it simulates a fire on the outside of the grease duct and incorporates a subsequent hose stream test. The integrity and stability of the duct is evaluated for a 1-hour or 2-hour rating period, and the through penetrations must comply with ASTM E-814 5

6 Additional Flamebar BW11 Properties and Classifications When Installed Without Insulation Flamebar BW11 Fire Duct is classified by Underwriters Laboratories in accordance with ISO 6944 (1985) for up to 4 hours as a smoke and fire duct. ASTM E-119 Full Scale Engulfment Test: Two Hour Fire Rating. Includes the Hose Stream Test with water Pressure of 30psi for 2.5 min ASTM E-84 / UL723 Surface Burning Characteristics: Flame Index: 9.4; Smoke Index: 0.2 Artificial Weather of Flamebar BW11: The samples have undergone over 22,000 hours of alternate UV and condensation cycling which is considered excessive in duration terms, normally 1,000 hours is sufficient to predict whether a material is suitable for exterior semiexposed conditions. 22,000 hours is equivalent to 60 years external exposure. Expansion of Flamebar BW11: As all steel expands with temperature, there will naturally be an expansion of fire duct under fire conditions as follows: At 2012 F an expansion of in per in At 1112 F an expansion of in per in At 806 F an expansion of in per in Commercial kitchen extract ductwork presents a particular hazard in that combustible deposits can accumulate on its internal surfaces. Therefore, the ductwork should resist fire from inside the duct (Type B) and from outside the duct (Type A). Fire dampers must not be used: 6

7 The Firespray Flamebar BW11 System grease duct is constructed from 20-gauge galvanized sheet metal in flanged sections of up to 59 in length with a maximum cross section of 49 x 49. The duct is then degreased and factory fire sprayed with Flamebar BW11 to a thickness of approximately 0.04 (1 mm) to give a finished product. The ductwork is assembled on site utilizing Flamebar gaskets and sealants. For Grease Duct applications requiring a shaft enclosure or a zero clearance installation, the ductwork can then be wrapped with Unifrax FyreWrap Elite 1.5 or Max 2.0 duct insulation, consisting of two layers applied directly to the duct surface. All of the above components are necessary to comply with the ASTM E-2336 and UL 1978 test requirements. Detailed below are all aspects of the fabrication, installation and insulation of the Flamebar BW11 Grease Duct System: Fabrication: Table 1 itemizes fabrication details for Flamebar BW11 Grease Duct rectangular ductwork based on SMACNA HVAC Duct Construction Standard, 2 nd Edition, for static pressures up to 6 wg, positive or negative, constructed of G60 coated galvanized steel of lockforming grade to ASTM A924, coated with of Flamebar BW11. Table 1: Flamebar BW11 Grease Duct Fabrication Details, 120 min Fire Endurance Reinforcement: The Mechanical Code for grease ducts stipulates that there shall be no protrusions into the duct, so conventional tie rod reinforcement would not be acceptable. Flamebar Grease Duct utilizes rolled steel angle (RSA) spot welded at 6 centers around the external perimeter of the duct at midsection per the schedule in Table 1 above, and is illustrated in Figure 1 to the right. Figure 1: Duct Reinforcement Flanges: The Grease Duct system utilizes Ductmate flanges for sides up to 42 (Figure 3), or alternatively RSA Flanges for sides up to 49 (Figure 2). Grease Ducts flanged with Ductmate 7

8 would have 3/8 bolts at the corners and intermediate G-Clamps at 12 maximum spacing. Angle Flanges would have 3/8 bolts at the corners and at 6 maximum centers. Ductmate flanges would have Flamebar Fire Sealant applied to the inner seam between the flange and the duct as shown in Figure 3, in addition to the corners. Flamebar self-adhesive gasket is applied in between all joints during installation, with two layers of gasket (positioned side by side, essentially double width) required for ducts with sides greater than 24. Care must be taken to apply the gasket along the inner edge of the flange in order to avoid the formation of a potential grease trap. Gasket can be installed in one or more strips which must all fully overlap each other at intersecting corners (or ends) as shown in Figure 6. Gasket ends must never be simply butted up against each other. The intumescent impregnated closed cell gasket supplied with the system ensures that joint leakage is a non-issue when properly applied (UL 1978 Grease Leakage Test). Figure 2: Steel Angle (RSA) Flanged Joint Figure 3: Ductmate Flange with G-Clamp All Flamebar BW11 duct segments shall be fabricated with Pittsburgh Lock Seams or Grooved Corner Seams incorporating fire sealant as illustrated in Figures 4 and 5. Figure 4: Duct Seam Figure 5: Duct Seam Figure 6: Ductmate Flange with Gasket Access Doors for Insulated Flamebar to ASTM E-2336 & UL 1978: Field fabricated and prefabricated grease duct access doors are permitted for use with Flamebar BW11 Grease Duct Systems. Installation details are provided in Figure 7, either as field fabricated or prefabricated Ductmate Ultimate & F2-HT 8

9 Figure 7: Insulated Access Door Assembly Table 2 itemizes all relevant support information for the installation components of Flamebar BW11 Grease Duct related to the trapeze style supports which are spaced out at 59 horizontal centers maximum, for all sizes up to 49 on a side. When designing and testing fire resistant ductwork, it is critical that the reduction on tensile strength of steel under fire load is given proper consideration. For example, it must be recognized that the pull-out load of an anchor under fire conditions is significantly less than at ambient temperature. By specifying the Flamebar BW11 System, it can be assured that these issues have been adequately addressed. Table 2: Grease Duct Support Details Field Repair: In the event that a duct segment sustains limited damage on site, contractors can perform the repair as illustrated in Figure 8. The replacement panel is to be 20-gauge minimum, oversized by 1.5 on all sides, coated by the licensed spray facility, and fire sealed and fastened as shown. If a duct segment is simply scratched with slight damage to the coated surface, contractors may reapply coating with a touch up kit provided by the spray facility. Figure 8: Duct Segment Repair 9

10 Field Modification: If necessary, the length of a Flamebar BW11 duct segment can be reduced in the field. The duct can be cut to the desired length utilizing standard sheet metal cutting tools, and replacement Ductmate flanges can be installed (per Table 1 specification). The replacement flanges do not require coating. The new Ductmate flanges should then be inserted over the raw end of the duct, riveted or spot welded in place (at 6 centers), and require Flamebar Caulk to be smoothed along the inner seam of the flange and duct. Caulk should also be applied to the corners. Recognizing that field measurements for a duct project seldom align on site without a final measurement and modification, it can be good practice to order the coated duct segments with at least one select segment that has a flange on one end only, with the other end left raw. The duct segment can then be easily cut to size with flanges fastened in place as described in the preceding paragraph. Outdoor Installation: While the coating on Flamebar BW11 ductwork is non-hygroscopic and particularly durable, all duct segments installed outdoors should have a protective water based paint applied to the coated surface of the duct, and ideally incorporate a watershed structure over the duct system in order to avoid any pooling of water on the top surface. Firespray International should be contacted for additional information on the recommended paint or alternative methods of protection. Supports for Risers: Vertical ducts are supported by spanning floor slabs with appropriately-sized bearer support steel. The maximum height between floor supports is 4 yards. Alternatively, cantilever type supports may be utilized. Both methods are illustrated in Figure 9 and incorporate 3 x 3 x ¼ steel angle welded to the side of the duct during the fabrication process and fastened to the bearer support. Note that the angle steel fastened to the duct which forms part of a Through Penetration Firestop System, as described in the next section, is also considered a duct support. Figure 9: Supports for Risers 10

11 Through Penetration Seals: Where a ventilation duct penetrates a fire rated wall, floor or ceiling assembly, the resulting opening around the duct shall be properly fire stopped. Figure 10 below illustrates a typical condition for both horizontal and vertical orientations. Figure 10: Penetration Seals The following Through Penetration Firestop Systems are UL Classified for use with the Flamebar BW11 Coated Steel fire rated duct systems: C-AJ-7029, C-AJ-7030, F-A-7017, F-B-7005, W-L-7133, W-L-7160 ( UL Category: XHEZ) 11

12 In order to fully comply with the listing to ASTM E-2336 and testing to UL 1978, and secure a one or two hour rated enclosure with zero clearance to combustibles, only Unifrax FyreWrap Elite 1.5 or Max 2.0 may be used to insulate Flamebar BW11 Grease Duct. The wrapping of the duct must adhere to the specific instructions provided below, which are provided in greater detail in Unifrax s installation instructions. Additional information on the Unifrax products can be found on their website, Insulation shall be applied in a minimum of two layers. The first layer of insulation can be installed with transverse (perimeter) joints butted and minimum 3 joint size longitudinal overlaps on the top side of the horizontal ducts. All overlaps for the second layer are required to be a minimum of 3. For the second layer, transverse (perimeter) overlaps of adjacent blankets may be installed using one of the following three methods as shown in Figure 11 below. Insulation is attached to the duct with steel bands for ducts with sides of 24 or less, and with both steel bands and weld pins on one surface of the duct (bottom for horizontal, and back for vertical) for ducts up to 49. Weld pins shall be attached to 1 x 1 20-gauge steel plates that are riveted to the Flamebar duct with ⅛ diameter steel blind pop rivets. All pins and bands locations and type are per Unifrax s standard installation instructions for Fyrewrap Elite 1.5 or Max 2.0. Figure 11: Insulation of Flamebar BW11 Grease 12

13 Field Installation Inspection Checklist: Site installations are inspected by Firespray and/or its Licensees to ensure full conformance with specification (refer to drawing STD-380, next page, Figure 13) with particular attention to the items listed in the standard form below, Figure 12: Figure 12: Sample Inspection Checklist 13

14 Figure 13: Firespray STD

15 Drafted below is a typical specification in CSI format for Flamebar BW11 fire rated ductwork, including Grease Duct. While fairly comprehensive, the document may not address all related subjects to the level of detail desired, but it can be used as the basis for an actual product specification and modified as desired. FIRE RATED AND GREASE DUCTWORK SYSTEMS PART 1 GENERAL 1.1 Summary A. Provide an Underwriter s Laboratory classified 2-hour fire resistive assembly as indicated on the drawings. The assembly shall provide the fire rating incorporating a specially enhanced duct construction with a factory applied coating of Flamebar BW11, for shaft, risers and horizontal duct systems. Ducted systems shall include, but not be limited to, utility dryer and toilet exhausts, stair and elevator pressurizing systems, smoke evacuation and make-up air systems and primary air-conditioning systems. B. Grease duct systems shall be an ASTM E2336 and UL 1978 tested product in compliance with IMC, UMC, and NFPA96 code. C. Specifically enhanced duct systems shall be manufactured in accordance with the relevant construction standards as published by Firespray International and as considered by UL and Intertek ETL Semko in their classification and listings of the Flamebar BW11 system. Any qualified licensed sheet metal contractor may manufacture the ductwork to the Firespray construction standard. A Licensee appointed by Firespray International shall apply the Flamebar BW11 coating. Any qualified, licensed installer may install the coated ductwork, in accordance with the Firespray construction standard. Upon completion, the Flamebar BW11 Licensee shall inspect the installation to ensure compliance with the relevant published Firespray construction standard, the requirements of the UL classification requirements, and the Intertek ETL listings. On confirmation of the required compliance, the Licensee shall issue a certificate of conformity. 1.2 References A. SMACNA (Sheet Metal and Air Conditioning Contractors National Association) Standards: Comply with the detailing required for this ductwork assembly as shown in the Firespray International relevant published construction standards. B. NFPA (National Fire Protection Association): Comply with ANSI/NFPA 90A Standard for the Installation of Air Conditioning and Ventilation Systems and ANSI/NFPA 90B Standard for the Installation of Warm Air Heating and Air-Conditioning Systems. Comply with ASTM E 2336 requirements for Grease duct systems 15

16 C. UL File #18284: Report on Ventilation Duct and Through-Penetration Firestop System. D. ASTME E-119: Compliance as Intertek ETL Semko test and evaluation number This includes compliance with the hose stream test requirements. E. ISO 6944 (1985): Fire Resistance Tests Ventilation Ducts. F. ISO 834 (1975): Fire Resistance Tests-Elements of Building Construction. G. ASTM E-2336: Fire Resistive Grease Duct Enclosures Systems 1.3 Submittals A. Shop Drawings. Submit properly scaled and dimensioned layouts for each fire rated system showing individual identifying marks for each component of the system in accordance with the UL and Intertek ETL Semko classifications and listing requirements. B. Record Drawings. At project closeout submit record drawings of installed ductwork systems including accessories, outlets and inlets. C. Certificate of Conformity. Provided by the manufacturer s local Licensee. The qualified Licensee s representative shall inspect the completed installations and submit a certificate in the name of the Owner certifying compliance with the relevant Firespray International Construction and Installation standards. 1.4 Quality Assurance A. All ductwork used as part of this system shall be manufactured by a licensed and qualified and insured sheet metal contractor with a minimum of five (5) years experience with the manufacture of ductwork systems. B. All ductwork to be used on fire rated systems shall be inspected at the factory of the local Flamebar BW11 Licensee, to confirm compliance with the relevant enhanced construction standards and with the shop drawings. After inspection the ductwork shall be degreased and coated with BW11. After coating and curing, each individual section shall be inspected and labeled in accordance with the UL classification and Intertek Listing requirements. Records of all pieces shall be kept for inspection by the Authority Having Jurisdiction (AHJ). 1.5 Delivery, Storage, and Handling A. Protect factory fabricated and coated ductwork, accessories and purchased products from damage during shipping, storage and handling. Prevent end damage, and prevent dirt and moisture from entering ducts and fittings. B. Store ductwork indoors and dry, and protect from damage from other trades. Where necessary to store outside for a short time period, store above grade on skids and enclose with secured waterproof wrapping. 16

17 PART 2 PRODUCTS 2.01 Manufacturer of Flamebar BW11 Coating and Ancillaries A. Approved Manufacturer: Firespray International, 101 Tiffany Dr, Waynesboro, VA Tel: (972) Coating Flamebar BW11 2. Ancillaries including Gasket, Caulk, G-Clamps, etc. as supplied by the Manufacturer. 3. Moisture absorption: The system is considered non-hydroscopic with resulting equivalent to sixty years external exposure by artificial weatherometer. 4. Chemical resistance: The coating is chemically resistant to many acids and solvents. 5. Smoke and toxic emissions: Meets NFPA 90 Smoke emissions and toxic fume emission. Tested in accordance with UL 723 (ASTM E84). 6. Cleaning: Smooth monolithic finish cleans easily with soap and water or the manufacturers recommended cleaning solutions. 7. Color and finish: Natural buff finish of the factory applied monolithic coating can be painted with any water-based paint. B. Appointed Licensee: Please contact Firespray International at (972) or info@firesprayusa.com for a current listing of Flamebar Licensees in North America Ductwork Construction A. Exposed ductwork materials: Where ductwork is indicated to be exposed to view in occupied spaces, provide materials which are free from visual imperfections including pitting of the finished coating, marks, surface imperfections, including that which would impair painting. Oil based paint shall not be used on Flamebar BW11 coating. a. Outer coating: Provide a factory applied coating as per the manufacturer s recommendation. The coating should be applied and cured in a controlled environment as required by the UL classification and Intertek listing requirements. b. Ductwork Metal and Gages: Fabricate ductwork from galvanized steel sheet. Thickness shall be as per the relevant Firespray construction standards. B. Comply with ASTM A527, Lock forming quality. C. Comply ASTM A 525 G90 Zinc coating, mill phosphate. D. Comply with Firespray International standards (STDs) for rectangular, circular and flat oval ductwork (STDs 353, 355 and 357 respectively). Copies of these are available on request. E. Duct Sealant: As supplied by Firespray International. 17

18 F. Gasketing: As supplied by Firespray International. G. G-Clamps: As supplied by Firespray International. H. Duct Access Doors: Removable access doors where required to be as shown on the relevant construction standard as provided by Firespray International Fabrication Ductwork shall be fabricated in accordance to the relevant construction standard as issued by Firespray International 2.04 Insulation Insulation applied to Flamebar BW11 Grease Duct shall be Unifrax Fyrewrap Elite 1.5 or Max 2.0, and installed per Unifrax s product installation instructions PART 3 EXECUTION 3.01 Inspection Examine areas and conditions under which ductwork is to be installed. Do not proceed with the work until unsatisfactory conditions have been corrected in a manner acceptable to the manufacturer Installation of Ductwork Install in accordance with the relevant Firespray construction standard and any applicable local codes. COPYRIGHT Firespray International Ltd. All Rights Reserved Revision