CERTIFICATE OF APPROVAL No CF 5073 LEMINAR AIR CONDITIONING INDUSTRIES L.L.C.

Transcription

1 CERTIFICATE OF APPROVAL No CF 5073 This is to certify that, in accordance with TS00 General Requirements for Certification of Fire Protection Products The undermentioned products of PO Box 33539, Dubai, United Arab Emirates Tel: Fax: Have been assessed against the requirements of the Technical Schedule(s) denoted below and are approved for use subject to the conditions appended hereto: CERTIFIED PRODUCT Leminar Air Conditioning Industries L.L.C. FFC Fire Rated Steel Ductwork Systems TECHNICAL SCHEDULE TS48 Smoke Control and Fire Resisting Ductwork Systems Signed and sealed for and on behalf of CERTIFIRE Sir Ken Knight Chairman - Management Council Page 1 of 28

2 1. This approval relates to the use of the above ductwork systems in providing fire resistance of up to 240 minutes stability, integrity and insulation (duct A) and up to 240 minutes stability and integrity and 120 minutes insulation (duct B), as defined in BS 476: Part 24: 1987 (ISO 6944: 1985). Subject to the undermentioned conditions, the ductwork systems will meet the relevant requirements of BS 9999 for fire resisting compartment ductwork systems, for periods of up to 240 minutes (dependant upon design limitations) when used in accordance with the provisions therein. 2. This certification is designed to demonstrate compliance of the product or system specifically with Approved Document B (England and Wales), Section D of the Technical Standards (Scotland), Technical Booklet E (N. Ireland). If compliance is required to other regulatory or guidance documents there may be additional considerations or conflict to be taken into account. 3. The ductwork systems are approved on the basis of: i) Initial type testing ii) Audit testing at the frequency specified in TS48 iii) A design appraisal against TS48 iv) Certification of quality management system to ISO 9001: v) Inspection and surveillance of factory production control 4. The ductwork systems comprise FFC steel ductwork, with stone mineral wool insulation fitted around the outside of the steel ductwork where insulation performance is required. 5. This approval is applicable to insulated and uninsulated FFC steel ductwork systems as described within this Certificate. 6. The ductwork systems shall be mechanically supported from floor and/or wall constructions or structural steel members having a fire resistance of at least the same period as the ductwork systems. 7. The approval relates to on-going production. Product and/or its immediate packaging is identified with the manufacturers name, the product name or number, the CERTIFIRE name or name and mark, together with the CERTIFIRE certificate number and application where appropriate. Page 2 of 28 Signed

3 Leminar Air Conditioning Industries L.L.C. FFC Insulated & Uninsulated Steel Scope: Mild steel, galvanised steel or stainless steel ventilation ducts, smoke extract/outlet ducts and kitchen extract ducts coated with FFC 250 with a nominal dry film thickness of 0.20mm for fire resistance periods up to 120 minutes and 0.35mm for fire resistance periods up to 240 minutes. Orientation: Horizontal and vertical. Insulation: Uninsulated and insulated. Maximum fire resistance periods: Fire outside (duct A) 240 minutes stability & integrity & 120 minutes insulation. Fire inside (duct B) minutes stability & integrity & 120 minutes insulation. Rectangular ducts The minimum construction requirements for the steel duct ( see Figures 6, 7, 9, 11 & 13) are as follows: Wall thickness - minimum 0.8mm-thick steel sheet (Table 1), Longitudinal seams - Pittsburgh Lock or Grooved Corner Seam, Cross joints - rolled steel angle flanged cross-joints or equivalent roll-formed sheet steel profile cross-joints, Maximum section length mm but 1260mm for 240 minutes fire resistance, Maximum size 3000mm wide x 2500mm high (Table 1). Table 1 minimum steel thickness for rectangular ducts Type of duct Ventilation Smoke outlet/extract Kitchen extract Maximum size of duct (longer side) - mm Note 1 0.8mm thick for fire resistance periods up to 120 minutes. resistance periods over 120 minutes. Note 2 1.0mm thick for fire resistance periods up to 120 minutes. resistance periods over 120 minutes. 1.0mm thick for fire 1.2mm thick for fire Page 3 of 28 Signed

4 Stiffeners: For duct sections with a size of more than 400mm longer side, (with the exception of ducts up to 600mm longer side x up to 1260mm long) the duct is fitted with stiffeners of at least S3 (DW/144) rating at mid-length, as listed in Figures 6, 7, 9, 11 & 13. The stiffeners are fitted on all four sides and welded at the corners. This construction is suitable for duct sizes up to 2000mm wide x 1200mm deep. Where either duct dimension exceeds 1200mm a central tie rod is fitted per cross joint. For ducts larger than 2000mm x 1200mm the duct is fitted with stiffeners at the required centres and additionally the sheet panels of the duct are stiffened by beading, cross-breaking or pleating. For ducts wider than 2500mm the centres of the tie rods should not exceed 1200mm. Duct supports: Horizontal duct assemblies are supported by steel hangers that comprise a threaded steel studding drop rod on each side of the duct and a bearer (angle, slotted channel, channel or RHS) under the duct. Where duct systems exceed the tested duct dimensions the hangers (drop rods and bearers) supporting the duct assembly are increased in size to accommodate the extra loading imposed by the self-weight of the duct and any insulation. For insulated horizontal ducts, the steel bearer of each hanger at the base of the duct supports a steel spreader plate (where required) and a calcium silicate board spacer, 100mm wide x 25mm thick. The steel bearer is located within the thickness of the insulation. Alternatively the calcium silicate board spacer may be made up with layers of the board to be of at least the same thickness as the insulation. The maximum design stresses that unprotected steel hangers can bear in the standard fire test are given in Table 2. Table 2 Maximum stress in steel hangers Fire resistance period - minutes Stress limit N/mm The maximum spacing of the hangers is 1500mm centres except for a fire resistance of 240 minutes in which case the maximum spacings is 1200mm. Where the duct width exceeds 1500mm, a central drop rod (same size as primary drop rods) is incorporated which supports the bottom of the duct (via the steel bearer) and also the top of the duct using a steel nut and large steel washer. Vertical ducts: The construction of vertical ducts is the same as for horizontal ducts. In order to support the duct system in the vertical orientation, steel sections are fastened to the steel duct, either along the two longer or shorter sides or on all four sides. The steel sections either span across the opening in the concrete floor or form part of a cantilever bracket that is fastened to the building structure. Details of the support of vertical ducts are given in Figure 16 (FFC drawing no. FFC/DETAIL/01 B ). Page 4 of 28 Signed

5 Insulation: A single or double layer of foil faced stone mineral wool insulation is fastened to the outside of the duct with steel pins, 2.5mm diameter, which are stud welded or pop-riveted to the steel duct with steel rivets. The stone mineral wool must have a minimum density of 155kg/m 3 and be noncombustible in terms of BS 476: Part 4 or 11. The pins are spaced at nominal 350 mm centres along the sides and soffit of horizontal ducts. On the sides of the duct the pins are positioned along the centre line of each vertical side. Where the duct height exceeds 1000mm, the pins are positioned in rows starting 50mm in from each longitudinal edge and with one row in the centre. The maximum spacing between rows is 500mm. On the soffit of the duct the rows of pins are positioned 50mm in from each longitudinal edge of the duct, with extra rows between (depending on the width of the duct) so that the maximum spacing between rows is 500mm. The stone mineral wool insulation board is pushed onto the steel pins and held in position with minimum 38mm-diameter spring steel washers. On the soffit of horizontal ducts the ends of the pins are bent over to ensure that the washers are retained in position. All board-to-board joints are bonded with a high temperature silicate adhesive. Joints at corners are also secured using pig-tail screws at maximum 500mm centres. All board joints are staggered between the layers of board by at least 300mm. Extra pieces of insulation, minimum 30mm thick, are attached over joints in the duct and stiffeners to ensure that the required thickness of insulation is maintained between all steelwork of the duct and the outside. These cover strips are not needed where the insulation thickness is 90mm or greater. Vertical ducts are clad in the same manner but with fixing pins on all four sides; the longer sides are clad in the same manner as the soffit of horizontal ducts. The required thickness of stone mineral wool insulation is: Table 3a - Duct A Fire outside Fire resistance period - minutes Thickness mm Table 3b - Duct B Fire inside Fire resistance period - minutes Thickness mm Table 3c Kitchen extract duct Fire outside Fire resistance period - minutes Thickness mm (3 x 45) For kitchen extract ducts as detailed in the Annex of BS 476: Part 24. Page 5 of 28 Signed

6 Access doors: Type details of the access door are shown in drawing no. FFC/AD/201 rev B (Figure 17). Type Details of the lagged access door are shown in drawing no. FFC/AD/202 rev A (Figure 18). Circular & flat oval ducts The minimum construction requirements for circular and flat-oval straight seamed and spirally wound steel ductwork (see Figures 8, 10, 12, 14 & 15) are as follows: Wall thickness - minimum 0.8mm-thick steel sheet (Tables 4a & 4b), Longitudinal and spiral seams - Grooved Seam or equivalent, Cross joints - rolled steel angle flanged cross-joints or equivalent roll-formed sheet steel profile cross-joints, Table 4a Minimum steel thickness for circular ducts Type of duct Ventilation Smoke outlet/extract Kitchen extract Maximum nominal diameter of duct - mm Note 1 1.0mm thick for fire resistance periods up to 120 minutes. 1.2mm thick for fire resistance periods over 120 minutes. Table 4b Minimum steel thickness for flat oval ducts Type of duct Ventilation Smoke outlet/extract Kitchen extract Maximum surface area per metre length m 2 /m Note 1 1.0mm thick for fire resistance periods up to 120 minutes. resistance periods over 120 minutes. 1.2mm thick for fire The spiral seam of spirally wound ducts must be at least equivalent to the grooved seam. Page 6 of 28 Signed

7 For flat oval ducts over 500mm wide x 150mm deep, tie rods, with a minimum diameter of 12mm, must be fitted between the top and bottom walls of the flat portion of the duct, as follows: for ducts between 500mm wide and 700mm wide, one tie rod is located at mid-width of the duct at 1000mm centres along the duct. for ducts between 701mm wide and 900mm wide, one tie rod is located at mid-width of the duct at 750mm centres along the duct. for ducts between 901mm wide and 1200mm wide, two tie rods are equi-spaced across the duct at 500mm centres along the duct. for ducts between 1201mm wide and 1800mm wide, tie rods are spaced at 250mm centres along the duct, alternating between one tie rod centrally located and two tie rods equi-spaced across the duct. Hangers: When designing supports for circular or flat-oval ducts similar principles must be followed to those for rectangular ducts. Insulation: For circular and flat-oval ducts that are required to satisfy the insulation criteria of BS 476: Part 24: 1987 the same thicknesses of stone mineral wool and fixing methods are used as for rectangular ducts, as shown in Figure 19. The fixing pins and washers are at 350mm maximum centres along the length of the duct and at maximum 500mm centres around the circumference of the duct. Penetration seals: The following methods are suitable for rectangular steel ducts. Similar methods can be used for circular and flat-oval ducts following the same principles with suitable modifications to take account of the duct shape. Option 1: This method is suitable for sealing gaps around uninsulated or insulated ductwork with up to four hours fire resistance when penetrating masonry or concrete walls and concrete floors. Duct lengths are joined via a profiled steel section contained within a standard HEVAC/HVCA damper installation frame, with the frame mounted centrally within the aperture in the wall or floor. The duct sections are connected to the profiled section using steel rivets at 75mm centres across the top and bottom and at 50mm centres on the sides of the duct. The damper installation frame incorporates building ties at approximately 300mm centres. These ties are mortared into nominally 50mm x 50mm cut-outs in the wall or floor. The remaining space between the wall and damper installation frame is filled with ordinary 4:1 mix sand/cement mortar. No other materials are used in the construction of the penetration seal unless internal tie rods are required as described in other sections of this certificate. Page 7 of 28 Signed

8 Option 2: This method is suitable for sealing gaps around uninsulated or insulated ductwork with up to two hours fire resistance when penetrating masonry or concrete walls and concrete floors. The duct passes through the wall or floor leaving a gap of up to 100mm between the duct and the reveal of the opening in the wall or floor. The duct rests on a nominal 90mm-wide strip of calcium silicate board underneath the duct. The thickness of the strip is appropriate to the gap width. The gap around the duct is then packed with the same stone mineral wool that is used to clad the insulated duct systems, leaving a 30mm rebate around the duct on each face of the wall. The rebate is filled with Hilti CP 611A intumescent mastic prior to a 50mm x 50mm x 3mm-thick steel angle being attached around the duct on all four sides on each face of the wall. The angle is attached to the duct using M8 steel bolts at nominal 125mm centres. The angle is not attached to the wall. No cross joints or stiffeners are needed within the penetration seal. Option 3: This method is suitable for sealing gaps around insulated ductwork with up to two hours fire resistance when penetrating masonry or concrete walls and concrete floors. The duct passes centrally through the aperture in the wall or floor. Two steel angle frames, 50mm x 50mm x 5mm thick, are fastened around the duct centrally within the thickness of the wall or floor with a gap of approximately 50mm between them. The maximum permissible gap between the steel angles and the wall or floor all around the duct is 100mm. The space between the two angles up to the wall and the space between the outside of the angles and the surface of the wall or floor is filled with the same stone mineral wool that is used to clad the insulated duct systems. Cover strips of calcium silicate board, at least 12mm thick, are screwed to the face of the wall or floor on both sides of the seal all around the duct using suitable steel fixings into noncombustible plugs at maximum 300mm centres. The strips must overlap the wall by at least 75mm and they must fit against the duct surface. Two strips of 40mm wide x 3mm thick steel are secured around the inside of the duct using M10 steel bolts, three each side and six along the top and bottom. One strip is located under each of the angle frames. Two M12 steel tie bars are passed vertically through the duct (equally spaced across the duct) being held with a nut each side of each duct wall. The tie bars are located within one of the steel sleeves inside the duct. Option 4: This method is suitable for sealing gaps around uninsulated or insulated ductwork with up to two hours fire resistance when penetrating masonry or concrete walls and concrete floors. Page 8 of 28 Signed

9 The duct passes centrally through the aperture in the wall or floor. One steel angle frame, 50mm x 50mm x 5mm thick, is fastened around the duct centrally within the thickness of the wall or floor. The space between the duct and the wall or floor is packed with ceramic mineral wool. Pieces of 12mm-thick calcium silicate board are secured to the face of the wall or floor on one side of the seal all around the duct using suitable steel fixings into non-combustible plugs at maximum 300mm centres. The strips must overlap the wall or floor by at least 75mm and they must fit against the duct surface. A steel frame formed from 1.2mm-thick galvanised sheet J- sections, or similar, is secured, using suitable steel fixings into non-combustible plugs at maximum 300mm centres, to the face of the other side of the wall or floor and riveted to the duct. The J-sections must overlap the face of the wall or floor by at least 75mm. All joints between the strips of calcium silicate board, between the strips and the wall or floor and between the strips and the duct are sealed with a fire rated intumescent acrylic mastic. Option 5: This method is suitable for sealing gaps around uninsulated or insulated ductwork with up to two hours fire resistance when penetrating drywall partition systems. The duct passes centrally through the aperture in the partition. The duct is arranged so that the join between sections is located within the depth of the partition. For rectangular ducts, the gap between the duct and the opening in the partition is packed with strips of Fenland Firetech Board insulation, described as a stone mineral wool type insulation, with the foil facing removed. For circular ducts, the space between the duct and the perimeter of the opening is packed with two layers of Fenland Firetech Board insulation. Each layer is cut to shape and prepared in two halves which are then installed such that the joins in the two layers are staggered by 90. In both cases the insulation is finished flush with the face of the partition and covered by a 1.6mm-thick steel sealing flange on each face of the partition. For rectangular ducts, the flange is in the form of a sheet folded into an angle section nominally 105mm x 50mm with a 10mm-wide inward return along the edge of each leg. Two pieces are welded together to form an L-shape. The two L-shaped halves of the flange are then assembled around the duct and joined together by two pairs of nuts and bolts. For circular ducts, the flange is supplied in two halves which when joined together form a square plate with a circular opening with a 50mm-deep lip around its perimeter. The two halves of the flange are then assembled around the duct and joined together with steel sheet joining plates, each nominally 100mm x 75mm, fixed to the flange above and below the opening using steel rivets. In both cases the flange is attached to the duct using steel rivets at nominal 150mm centres and to the partition using drywall screws at nominal 75mm centres (circular ducts) or 150mm centres (rectangular ducts). The contact of the flange with the surface of the plasterboard lining is sealed with FFC intumescent acrylic sealant. Page 9 of 28 Signed

10 Figure 1 Horizontal duct supports 2 hour stability, integrity & insulation Page 10 of 28 Signed

11 Figure 2 Horizontal duct supports 2 hour stability & integrity, nil insulation Page 11 of 28 Signed

12 Figure 3 Horizontal duct supports 1 hour stability, integrity & insulation Page 12 of 28 Signed

13 Figure 4 Horizontal duct supports 1 hour stability & integrity, nil insulation Page 13 of 28 Signed

14 Figure 5 Example of minimum specification for steel ductwork with up to 2 hours fire resistance Longer Stiffening Minimum side, up Maximum Angle section gauge - mm to - mm spacing - mm rating Cross joint rating nil nil J3 Figure 10/ S3 Figure 18/19 J4 Figure 10/ S3 Figure 18/19 J4 Figure 10/ S4 Figure 18/19 J4 Figure 10/ S4 Figure 18/19 J5 Figure 10/ S5 Figure 18 J5 Figure 10/11 with tie-rod S5 Figure 18 J5 Figure 10/11 with tie-rod S6 Figure 18 J6 (50mm x 5mm RSA) with tie-rod S6 Figure 18 J6 (50mm x 5mm RSA) with tie-rods 1. Cross joint fixing rivet or spot 150mm centres. 2. Stiffener fixings rivet, spot weld or 150mm centres. 3. Longitudinal joints Corner Grooved (RAS) corner or Pittsburgh lock seam Sheet to sheet grooved (RAS) seam 4. Radius bends as DW/144 but, where required, splitters to be welded in. 5. All untreated steel, including spot welds, to be painted with a zinc rich primer. 6. Only steel/stainless steel rivets or huckbolts to be used. 7. All sealants to be intumescent. 8. All part identifications to be on inside of duct. 9. Tie-rods are steel rods, minimum size 10mm diameter. 10. References and Figures based on DW/144. Page 14 of 28 Signed

15 Figure 6 Rectangular ductwork specification - Fire outside (duct A) up to 4 hours stability and integrity Page 15 of 28 Signed

16 Figure 7 Rectangular ductwork specification - Fire inside & outside (duct B) up to 4 hours stability and integrity Page 16 of 28 Signed

17 Figure 8 Circular ductwork specification - Fire outside (duct A) up to 4 hours stability and integrity (maximum diameter is 1250mm) Page 17 of 28 Signed

18 Figure 9 Rectangular ductwork specification - Fire outside (duct A) up to 2 hours stability and integrity Page 18 of 28 Signed

19 Figure 10 Circular ductwork specification - Fire outside (duct A) up to 2 hours stability and integrity (maximum diameter is 1250mm) Page 19 of 28 Signed

20 Figure 11 Rectangular ductwork specification - Fire inside & outside (duct B) up to 3 hours stability and integrity Page 20 of 28 Signed

21 Figure 12 Circular ductwork specification - Fire inside & outside (duct B) up to 4 hours stability and integrity (maximum diameter is 1250mm) Page 21 of 28 Signed

22 Figure 13 Rectangular ductwork specification - Fire inside & outside (duct B) up to 2 hours stability and integrity Page 22 of 28 Signed

23 Figure 14 Circular ductwork specification - Fire inside & outside (duct B) up to 2 hours stability and integrity (maximum diameter is 1250mm) Page 23 of 28 Signed

24 Figure 15 Flat oval ductwork specification - Fire inside & outside (duct B) up to 2 hours stability and integrity Page 24 of 28 Signed

25 Figure 16 Typical support for vertical ducts Page 25 of 28 Signed

26 Figure 17 Camlock access panel (maximum size 600mm x 600mm) Page 26 of 28 Signed

27 Figure 18 Insulated access panel (maximum size 600mm x 600mm) Page 27 of 28 Signed

28 Figure 19 Arrangements of insulation for circular ductwork Page 28 of 28 Signed