ColumnClad System. Rigid fire protection solutions for structural steel columns and beams

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1 ZERO ODP ZERO GWP CI/SfB Rf7 July 05 (replaces September 04 issue) OZONE DEPLETING POTENTIAL GLOBAL WARMING POTENTIAL Construction type Structural Steelwork Rockwool supports FIRAS accredited installers ColumnClad System Rigid fire protection solutions for structural steel columns and beams As part of the comprehensive FirePro range of fire protection products, the new Rockwool/Lafarge ColumnClad system is a fast and efficient method of providing fire protection to structural steel columns and beams. The square edged, gypsum based ColumnClad boards are extremely robust and impact resistant. The excellent moisture resistance properties of the board enables encasement assembly to take place earlier in the construction programme of the main building envelope. The board has a flat white mineral tissue surface which can be decorated directly or alternatively a thin plaster skim coat can be applied prior to decoration. The ColumnClad System has been tested and assessed by the Building Research Establishment (BRE) and subsequently reviewed by the Association for Specialist Fire Protection (ASFP), prior to inclusion in the Yellow Book. This publication is regularly reviewed to ensure that it reflects the current philosophies of steel protection and it is therefore recommended that the principles of the Yellow Book are closely followed when a ColumnClad system is designed and applied. The non-combustible boards are stapled or screw fixed to each other around the column or beam to form a frameless encasement system. The new ColumnClad board extends the current tool box of Rockwool fire protection systems for structural steel columns and beams. Typical application showing the ColumnClad fire encasement system Advantages High impact resistance Quick and economical to install Moisture resistant Easy to decorate Column and beam applications Frameless system Up to 2hrs fire protection Euroclass A1 1

2 ColumnClad Performance and Properties The boards do not require a PVAC sealing coat prior to applying a decorative paint or plaster skim finish. Direct application may be applied to the board face subject to the following conditions: Do not decorate boards if damp atmospheric conditions exist. Boards must be dry and free of moisture. Board faces must be clean and free of oil or grease marks. All board joints should be reinforced with Lafarge jointing tape and filler. Protective angle bead should be applied at external corners Plaster skim finish applied once filler compound has set. Ceramic Tiling: Tiles can be applied using conventional tile adhesives without pre-treatment of the board. Board Fixings Fixing Options Composition and Manufacture ColumnClad boards are manufactured using synthetic additives, to provide superior fire and moisture resistant properties. Board Characteristics Non combustible: BS 476 Part 4 Euroclass A1: BS EN :02 Facings: Glass fibre non-combustible mineral tissue Quality assured: To EN ISO 9002 : 00 Moisture Content: < 2%: Appearance: White facings/square edged board Vapour Permeability: 15mm = 1.11g/MNS. mm = 0.85g/MNS. Thermal Conductivity: 0.W/mK Surface Hardness(penetrometer): 600 N Impact resistance to BS 5234/2: 15mm severe duty/mm severe duty Board Dimensions Thickness: Board density wt./board wt./board/m 2 boards/pallet dimensions mm mm kg/m 3 kg kg/m x x Fire Performance Reaction to fire classification: ColumnClad achieves an A1 classification in accordance with BS EN ISO :02. For the purposes of Approved Document B this is equivelant to a non-combustable product. 15mm and mm thick ColumnClad boards can be directly fixed to each other using proprietary 50mm chisel edged staples without the need for a supporting framework. (Alternatively mm boards may be screw fixed using Lafarge Grabber High Thread screws, without pre-drilling or counter sinking.) Note: Only staple fixings should be used to fix single layer 15mm board encasements. Components: Frameless Staple fixing: Use a proprietary gas powered cordless staple gun, fitted with a guide attachment (Paslode make suitable models). The boards can be stapled together at max. 150mm centres to form a rigid encasement protection for columns and beams. Frameless Screw Fixings: As an alternative to staple fixing, mm ColumnClad boards may be screw fixed together to form a rigid encasement using Lafarge Grabber High Thread Screws at max 0mm centres (see table below for sizes). Double Layer Encasements Where 15mm and mm boards are required to form a double layer, apply the mm layer first. Board joints must be staggered between respective layers. Construction ColumnClad thickness Screw Length Single Layer 15mm N/A mm 63mm Double Layer mm (2 x 15mm) N/A 40mm (2 x mm) 63mm then 76mm Accessories All accessories are available throughout the UK from most Rockwool distributors Fire Resistance: The ColumnClad frameless encasement system provides up to 2 hours boxed fire protection to Structural Steel Sections when tested to BS 476 Part 21. Jointing and finishing is not a requirement to meet the fire protection levels given, however the inclusion of services should be considered with caution. Moisture Resistance When tested to BS 12, ColumnClad boards absorbed less than 5% water by weight after 2 hours total immersion. The ColumnClad boards can be subjected to moisture throughout their installation, prior to the building envelope being sealed. When wetted and allowed to dry, the board will regain its strength and fire resistance. Finishes The completed column (or beam) lining provides a robust impact resistant smooth surface that will accept most kinds of decoration. The boards can be left unjointed or alternatively a taping and jointing treatment or skim plaster coat can be applied to give a smooth seamless finish. 2 Lightweight metal angle for board fixings at soffit and wall abutments. Size (Lafarge reference MFC2525) Lafarge Grabber High Thread Screws alternative board/board fixing option for mm ColumnClad encasements gauge for single layer board applications (Lafarge ref. 63DHT5) 76 8 gauge for double layer board applications (Lafarge ref. 76GHT5) Lafarge Grabber Self Tapping Screws board fixing to lightweight metal angles gauge for single layer 15mm ColumnClad (Lafarge ref. 32DST5) 38 6 gauge for single layer mm ColumnClad (Lafarge ref. 38DST5) Proprietary 50mm board to board chisel edged staple fixings available from gas staple gun manufacturers.

3 Table X. Section factor A/V (Hp/A) of structural steel I-sections for use only with Box encasements systems Section factors for Universal Columns Section Size Mass per Metre 3 Sides Hp/A 4 Sides Hp/A (mm) (kg) (m -1 ) (m -1 ) Fixing self tapping Grabber screws at max. 0mm centres to lightweight metal angle Section factors for Universal Beams Section Size Mass per Metre 3 Sides Hp/A 4 Sides Hp/A (mm) (kg) (m -1 ) (m -1 )

4 Design Considerations General ColumnClad boards are suitable for protecting structural steel columns and beams, with a section factor A/V (Hp/A) up to 260 calculated on the basis of box protection to 3 or 4 sides. Table 1 Hp/A table for 3 and 4 sided column fire encasement protection. Critical temperature 550 C 260 The ColumnClad board will protect universal column and beam sections listed in the ASFP Yellow book. Establishing ColumnClad board thickness In a fire, unprotected structural steel begins to lose its strength at temperatures around 550 C. Selection of the appropriate encasement is therefore essential. Further guidance can be found in Section 1 of the ASFP Yellow Book To establish the correct board thickness required for steel column and beam encasements the specifier should follow the procedure set out below: 1) Locate the appropriate size and mass of the column or beam (for common sizes see table X on previous page). Read off its Hp/A Factor depending on whether 3 or 4 sided protection is required ) Establish the period of fire resistance required. 3) Refer to the adjoining tables to determine the ColumnClad board thickness required. Table 1: Column fire protection (550 C) Table 2: Beam fire protection (550 C) Table 2A: Beam fire protection (6 C) Note: For castellated sections, adopt the above procedure then add % to the indicated thickness and specify the next highest board. Example: Column fire protection Requirement: 1 hour fire protection to kg/m steel column with 4 sided protection Solution Section factor Hp/A = (from table 1) Use single layer of 15mm ColumnClad Fire Resistance Required (minutes) Table 2 Hp/A table for 3 and 4 sided Steel Beams fire encasement protection. Critical temperature 550 C 260 Table 2A Hp/A table for 3 sided steel beam fire encasement protection. Critical temperature 6 C Fire Resistance Required (minutes) Fire Resistance Required (minutes) 4

5 Installation 4 sided frameless columns General The following notes are intended as general guidance only, addressing the basic sequence of installation. In practice consideration must be given to design criteria requiring specific project solutions. Cutting and fixing of ColumnClad boards To achieve a clean edge ColumnClad boards should be cut using a mechanical saw with suitable dust extraction. Boards can be staple fixed together at max. 150mm centres using a proprietary gas driven staple gun with an edge guide (Paslode make suitable models). Columns Frameless protection using ColumnClad noggins ColumnClad noggins are pre-cut and tightly friction fitted between the flanges on opposite sides of the column. The noggins are 100mm wide, fitted at max 1800mm centres, behind horizontal board joints, and at the top and bottom of the column section. ColumnClad boards are fixed to the noggins using 3 staples or screws. A 3mm air gap should be provided between the back of the ColumnClad board and the face of the steel flange. 50mm staples at 150mm centres ColumnClad boards staple fixed at 150mm centres For 4 sided column encasements: Always commence the cladding from the base of the column. ColumnClad boards are cut to widths and secured as shown. See figures C1 and C2. 1) Cut two full length ColumnClad boards equal to the flange width of the steel section, plus the thickness of board. 2) Cut one half length ColumnClad board equal to the depth of the steel section, plus the thickness of board, plus 6mm (for the air gaps at both flanges). Position the boards and staple fix board to board at max 150mm centres (alternatively, mm boards may be screw fixed at 0mm max. centres). 3) Cut a second half length board equal to the flange width plus the thickness of board. Position against the opposite flange and install fixings as stated above. 4) Continue boarding in the same manner, progressively working up the column. Ensure horizontal board joints are staggered on adjacent faces. Double layering Encasement For double layer boarding, install outer layer as per first layer, staggering board joints between layers. Cut outer boards to width making additional allowances necessary to cover the first layer. Note: Where 15mm and mm boards are required, apply the mm layer first. Board joints must be staggered between the respective layers. Additional Support Where web dimensions exceed 600mm additional support may be required for the encasement. For futher advice contact Rockwool. 3mm air gap Figure C1 ColumnClad board 100mm wide ColumnClad noggins at max 1.8m centres and behind abutting board joints Figure C2 4 sided protection to column. 3mm air gap between face of steel flange and board. ColumnClad noggins 100mm x 15-mm wedged into the web at the head and base of the column and behind the horizontal board joints. Additional noggins are not required behind joints in the second layer of a double boarded encasement. 50mm chisel edged staples at 150mm centres. Fixing of boards using a proprietary gas powered cordless staple gun Stagger joints on adjacent sides by min. 0mm. 4 sided Column Encasements 100mm wide ColumnClad noggins are tightly wedged between the steel flanges, at max. 1.8m centres, behind board jooints and at the head and base of the column. Facing boards are fixed to the noggins and each other using 50mm staples at 150mm centres. Adjacent boards should be half staggered. For double boarding, joints are staggered between layers. For column encasements, a 3mm air gap should be provided between the back of the board and the face of the column flange. 5

6 3 sided frameless column encasement 3 sided protection to steel columns Single layer frameless protection For 3 sided column protection Lafarge lightweight metal angles are fixed to the wall flange of the steel on opposite sides to provide fixing points to ends of board. Position such that the face of the angles are level with the edges of the flange and secure using appropriate shot fired (or spot welded) fixings at max. 600mm centres. 100mm wide ColumnClad noggins are then pre-cut and tightly friction fitted between both flanges at max. 1800mm centres and behind horizontal board joints. The ColumnClad encasement is fixed to the noggins using 3 staples or screws. ColumnClad boards are cut to widths shown in fig C3. The web encasement boards are cut to the depth of the steel section plus thickness of board plus 3mm (for the air gap tolerance between the board and flange). The Flange boards are cut to the same width as the column flange. Additional Support Where web dimensions exceed 600mm additional support may be required for the encasement. For futher advice contact Rockwool. Partitions Fixing Partitions and wall linings may be fixed directly to ColumnClad board, subject to the following conditions: 1) There are no special requirements for pressure resistance, such as lift shafts etc. 2) There are no special heavy duty or severe duty requirements as defined in recognised partition performance specification (e.g.bs 5234). Subject to these conditions, the partition C stud or Track may be secured directly to the ColumnClad encasement using Redidriva fixings with Lafarge 38DHTS screws at max 600mm centres (see figs C5 and B4 below). The column is progressivly encased and adjacent boards are half staggered. The boards are fixed to each other at 150mm centres using 50mm 10mm chisel edged staples, ensuring a clear 3mm air space is maintained between the back ColumnClad board and the steel column flange. The edges of the web encasement boards are fixed to the steel angles at 0mm centres using Lafarge self tapping Grabber screws (or equal approved, 32DST5 for 15mm boards and 38DST5 for mm boards). Screws should penetrate the angle by min. 10mm. Figure C3 3 sided protection to column. Wall abutment 4 sided column encasement with partition abutment Figure C5 Partition Abutment to Column Encasement 100mm wide ColumnClad noggins behind face board joints 3mm air space 25 x 25mm metal angle secured to column flange at 600mm centres 100mm wide ColumnClad noggins at 1.8m centres and behind board joints ColumnClad screw fixed at 0mm centres to metal angle using self tapping screws Redidriva fixing at 600mm centres. Lafarge 38DHT Screw Lafarge C stud Board to board staple fix at 150mm centres Figure C4 Wall Abutment. 3mm air space Beam Soffit Figure B4 Partition Abutment 50mm frameless staple fixings at 150mm centres Masonry wall 50mm long chisel edged staples. Self tapping screws at 0mm centres 3mm air space 25 x 25mm metal angle screw fixed to masonary wall Screw fixing appropriate to substrate at 600mm centres Wall plugs to be of non combustable type 50mm chisel edged staple fixings at 150mm centres 100mm wide ColumnClad noggins at 900mm centres and behind board joints. Redidriva fixing at 600mm centres. Partition track. Lafarge 38DHT Screw. 6

7 Fire encasement to beams Fire protection to steel beams selecting the right system When deciding on appropriate method of fire protection to structural beams, the specifier needs to be absolutely certain that selected system is both reliable and totally effective. Rockwool FirePro systems offer a wide selection of fire protection encasement solutions to structural steel beams. Rockwool BeamClad (previously known as Conlit 150) has been proven in service over many years. BeamClad is light and easy to install and offers a variety of fixing options (see Rockwool FirePro BeamClad data sheet). Where beam encasements are required to achieve a high impact resistance, or direct decoration ColumnClad boards may also be used for these applications. Key to diagrams on this page A Continuous 25x25mm lightweight metal angle shot fired or spot welded to top flange of beam. B Encasement board fixed to metal angle at 0mm max. centres using Grabber self-tapping screws. C ColumnClad encasement board (refer to tables 2 or 2A to determine thickness required). Ensure that adjacent board joints are staggered by at least 0mm. D 100mm wide (15 or mm thicj) ColumnClad noggins friction fitted into web at max 900mm centres and behind vertical board joints. Stagger position of noggins on adjacent webs. E ColumnClad encasement staple fixed to web noggins at max. 150mm centres. F 100mm wide ColumnClad noggins located at 900mm centres and behind soffit board joints. G Board to board fixings using 50mm chisel edged staples at max. 150mm centres. H Angle fixed to masonry at max. 600mm centres. Figure B1 Three sided encasement protection to beams. 3 sided protection to steel beams using ColumnClad The 25mm 25mm lightweight metal angle is shot fired or spot welded to the underside of the beam top flange at 600mm centres. 100mm wide ColumnClad noggins are tightly fitted between the top and bottom flanges at max. 900mm centres and behind vertical board joints. 100mm ColumnClad noggins are also fitted across the bottom flange of the beam at the location of board joints. The face boards are cut to suit the depth of the beam plus twice the thickness of the soffit board and are screw fixed to the metal angle sections at 0mm centres using Lafarge self tapping Grabber screws (which should penetrate channel by min. 10mm). Face boards are fixed to noggins using 50mm deep staples at 150mm centres. Soffit boards are cut to suit the width of the beam flange plus 2mm and fixed to the fascia boards using 50mm staples at 150mm centres. The beam is progressively encased and adjacent boards are half staggered (see fig. B1). The encasement board should be cut to fit as tight as possible to the concrete soffit. Any gaps caused by the irregularity of the concrete surface should be filled with Lafarge Acoustic Sealant. Additional Support Where web dimensions exceed 600mm additional support may be required for the encasement. For futher advice contact Rockwool. 2 sided beam protection Figure B5 A B C D B A D C E E H F G F G Figure B2 Beam Isometric A Figure B3 Beam Side elevation/section B A D B C G E F C E D G F 7

8 Typical Specification Clauses 1) The structural steel column/beam is to be fire protected using Rockwool ColumnClad board (a)mm thick to provide..(b) minutes fire resistance. (a) Insert ColumnClad board thickness (b) Insert period of fire resistance 2) Board to board joints should be fixed using 50 10mm proprietary staples at 150mm centres or alternatively mm boards may be fixed with Grabber High Thread screws at 0mm centres. Storage of Materials The recommendations of BS 8212:1995, Section 5, paragraph 31 must be complied with. The product must be stored in dry, well ventilated conditions with minimum temperature not less than 5 C. The boards should be kept off the floor and stored on timber pallets. Stock should be rotated, using oldest first. Site Conditions and Workmanship Useful Contacts Paslode Impulse Stapler ref: IM0/50 S16 Staple and fuel pack: G516 50mm CH Contact ITM Construction Products Technical Helpdesk on More information For further details visit our website at iwww.rockwool-firepro.co.uk. Temperature to be no less than 5 C. Site conditions to be in accordance with BS 8212:1995, Section 5, paragraphs Workmanship in accordance with BS and BS 8000: PT 8. Supply Available throughout the UK from Rockwool distributors. A list of distributors is available on request. Packaging ColumnClad boards are supplied shrink wrapped on timber pallets. Board Thickness Boards/pallet Weight/pallet 15mm kg mm kg Board Dimensions ColumnClad boards are manufactured in standard sizes of mm. Ordering When ordering please quote board thickness and area (m 2 ) requirement. Minimum order quantity: 1 pallet load 15mm boards: 1 pallet = 108 m 2 mm boards: 1 pallet = 86.4 m 2 Health and Safety Cutting ColumnClad with power tools generates dust and should be kept to a minimum. If significant dust is generated when working with the product, suitable respiratory protection should be worn, usually a dust mask. Heavy products should only be lifted in the correct way using mechanical handling equipment where necessary. Metal components should be cut and handled carefully to avoid cuts. Environment Rockwool products rely on trapped air for their thermal properties, which has neither ozone depleting nor global warming potential. Rockwool Limited Pencoed. Bridgend. CF35 6NY info@rockwool.co.uk Web: Rockwool Limited reserves the right to alter or amend the specification of products without notice as our policy is one of constant improvement. The information contained in this data sheet is believed to be correct at the date of publication. Whilst Rockwool will endeavour to keep its publications up to date, readers will appreciate that between publications there may be pertinent changes in the law, or other developments affecting the accuracy of the information contained in this data sheet. The above applications do not necessarily represent an exhaustive list of applications for ColumnClad. Rockwool Limited does not accept responsibility for the consequences of using ColumnClad in applications different from those described above. Expert advice should be sought where such different applications are contemplated, or where the extent of any listed application is in doubt. 8