Section_07_81_00_-_Spray-Applied_Fireproofing.pdf

SECTION 07 81 00

SPRAY-APPLIED FIREPROOFING

02/11

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASSOCIATION OF THE WALL AND CEILING INDUSTRY (AWCI)

AWCI TM 12-A (1997; 3rd Ed) Standard Practice for the Testing and Inspection of Field Applied Sprayed Fire-Resistive Materials; An Annotated Guide

ASTM INTERNATIONAL (ASTM)

ASTM E1042 (2002; R 2014) Acoustically Absorptive Materials Applied by Trowel or Spray

ASTM E119 (2018) Standard Test Methods for Fire Tests of Building Construction and Materials

ASTM E605/E605M (1993; R 2015; E 2015) Standard Test Methods for Thickness and Density of Sprayed Fire-Resistive Material (SFRM) Applied to Structural Members

ASTM E736 (2000; R 2011) Cohesion/Adhesion of Sprayed Fire-Resistive Materials Applied to Structural Members

ASTM E759/E759M (1992; R 2015; E 2015) Standard Test Method for Effect of Deflection on Sprayed Fire-Resistive Material Applied to Structural Members

ASTM E760/E760M (1992; R 2015; E 2015) Standard Test Method for Effect of Impact on Bonding of Sprayed Fire-Resistive Material Applied to Structural Members

ASTM E761/E761M (1992; R 2015; E 2015) Standard Test Method for Compressive Strength of Sprayed Fire-Resistive Material Applied to Structural Members

ASTM E84 (2018a) Standard Test Method for Surface Burning Characteristics of Building

Materials

ASTM E859/E859M (1993; R 2015; E 2015) Standard Test Method for Air Erosion of Sprayed Fire-Resistive Materials (SFRMs) Applied to Structural Members

ASTM E937/E937M (1993; R 2015; E 2015) Standard Test Method for Corrosion of Steel by Sprayed Fire-Resistive Material (SFRM) Applied to Structural Members

ASTM G21 (2015) Standard Practice for Determining Resistance of Synthetic Polymeric Materials to Fungi

ICC EVALUATION SERVICE, INC. (ICC-ES)

ICC-ES AC23 (2012; R 2016) Acceptance Criteria for Sprayed Fire-resistant Materials (SFRMs), Intumescent Fire-resistant Coatings and Mastic Fire-resistant Coatings Used to Protect Structural Steel Members

UNDERWRITERS LABORATORIES (UL)

UL 263 (2011; Reprint Mar 2018) UL Standard for Safety Fire Tests of Building Construction and Materials

UL Fire Resistance (2014) Fire Resistance Directory

1.2 SYSTEM DESCRIPTION

1.2.1 General Requirements

Protect all structural steel and roof deck in areas indicated on the drawings with spray-applied fireproofing to a fire resistance 1 hour-rating.

1.2.2 Fire Resistance Rating

Fire resistance ratings shall be in accordance with the fire rated assemblies listed in UL Fire Resistance. Proposed materials not listed in UL Fire Resistance shall have fire resistance ratings at least equal to the UL Fire Resistance ratings as determined by an approved independent testing laboratory, based on tests specified in UL 263 or ASTM E119. Submit reports and test records, attesting that the fireproofing material conforms to the specified requirements. Each test report shall conform to the report requirements specified by the test method. For the underside of the decking use metal lath installed prior to the fireproofing material or Rigid Board Fireproofing Material as outlined in the UL Fire Resistance Directory Volume 1. Apply fireproofing to structural steel members, with hourly fire resistance ratings and in accordance with the UL design or approved equivalent. Use unrestrained fire resistance ratings, unless the architect/engineer has specified that the degree of thermal restraint of the construction meets or exceeds the degree of thermal restraint of the tested assembly. Performance tests shall be in accordance with ASTM E119.

1.2.3 Evaluation Reports - ICC-ES Reports

Materials shall be evaluated in accordance with ICC-ES AC23. ICC-ES Reports shall be included as part of the Submittals below. The reports will identify the product as code compliant and having met the physical performance requirements outlined in paragraphs "Dry Density and Cohesion/Adhesion" through "Air Erosion".

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for [Contractor Quality Control approval. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submittals with an "S" are for inclusion in the Sustainability eNotebook, in conformance to Section 01 33 29 SUSTAINABILITY REPORTING.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-03 Product Data

Fireproofing Material; G

SD-04 Samples

Spray-Applied Fireproofing; G

SD-06 Test Reports

Fire Resistance Rating; G Field Tests; G Evaluation Reports; G

SD-07 Certificates

Installer Qualifications; G Surface Preparation Report; G Manufacturer's Inspection Report; G

1.4 QUALITY ASSURANCE

1.4.1 Installer Qualifications

Engage an experienced installer that is certified, licensed, or otherwise qualified by the spray-on fireproofing manufacturer as having the necessary experience, staff, and training to install the manufacturer's products in accordance with specified requirements. Submit manufacturer's certification that each listed installer is qualified and trained to install the specified fireproofing. Show evidence that each fireproofing installer has had a minimum of 3 years experience in installing the specified type of fireproofing. Each installer of fireproofing material shall be trained, have a minimum of 3 years experience and a minimum of three installations using fireproofing of the type specified. A manufacturer's willingness to sell its products to the Contractor or installer does not infer qualification of the buyer.

1.4.2 Pre-Installation Meeting

Hold a meeting with the installer, field testing agency, the manufacturer, subcontractors (whose employees come into contact with the fireproofing), and the Contracting Officer prior to the installation of any fireproofing material to review the substrates for acceptability, method of application, applied thickness, patching, repair, inspection and testing procedures.

1.5 DELIVERY, STORAGE, AND HANDLING

Deliver packaged material in the original unopened containers, marked to show the brand name, the manufacturer, and the UL markings. Keep fireproofing material dry until ready to be used, and store off the ground, under cover and away from damp surfaces. Damaged or opened containers will be rejected. Apply material with shelf-life prior to expiration of the shelf-life.

1.6 PROJECT/SITE CONDITIONS

1.6.1 Temperature

Maintain substrate and ambient air temperatures above 40 degrees F during application and for 24 hours before and after application. Maintain relative humidity within the limits recommended by the fireproofing manufacturer.

1.6.2 Ventilation

Provide adequate ventilation to properly dry the fireproofing after application. In enclosed areas, provide a minimum of 4 air exchanges per hour by forced air circulation.

PART 2 PRODUCTS

2.1 SPRAY-APPLIED FIREPROOFING

Provide spray-applied fireproofing material, including sealer, conforming to ASTM E1042, Class (a), Category A, either Type I or Type II, except that the dust removed shall not exceed 0.0025 gram per square foot of fireproofing material applied as specified in the project. Only products that have been evaluated at UL and bear and "investigated for exterior use" approval are allowed in waterfront areas where the fireproofing may be directly exposed to a natural body of water. Material shall be asbestos free, and shall resist fungus for a period of 28 days when tested in accordance with ASTM G21. Material shall have a flame spread of 25 or less and a smoke developed rating of 50 or less when tested in accordance with ASTM E84. Submit one sample panel, 18 inches square, for each specified type of fireproofing. Also, a designated sample area of not less than 100 square feet shall be prepared. Sample area shall be representative of typical installation of fireproofing including metal decks, beams, columns and attachments. Equipment, materials and procedures used in the sample area shall be the same as, or representative of, that to be used in the work. The sample area shall be approved prior to proceeding with fireproofing work in any other area. The approved sample area shall be used as a reference standard for applied fireproofing material. Sample area shall remain in place and open to observation until all spray-applied fireproofing is completed and accepted, at which time it may become part of the work.

2.1.1 Dry Density and Cohesion/Adhesion

Fireproofing shall have a minimum ASTM E605/E605M dry density and ASTM E736 cohesion/adhesion properties as follows:

2.1.1.1 Concealed Structural Components

Not Used

2.1.1.2 Exposed Structural Components

Fireproofing for exposed structural components, except where otherwise specified or indicated, shall have a minimum applied dry density of 22 pounds per cubic foot and a cohesion/adhesion strength of 434 psf.

2.1.1.3 Mechanical Rooms and Storage Areas

Not Used

2.1.2 Deflection

Spray-applied fireproofing shall not crack, spall, or delaminate when backing to which it is applied is subject to downward deflection 1/120 of 10 foot clear span, when tested in accordance with ASTM E759/E759M.

2.1.3 Bond-Impact

Spray-applied fireproofing material shall not crack, spall or delaminate when tested in accordance with ASTM E760/E760M.

2.1.4 Compressive Strength

The minimum compressive strength shall be 1000 psf when tested in accordance with ASTM E761/E761M.

2.1.5 Corrosion

Spray-applied fireproofing material shall not contribute to corrosion of test panels when tested as specified in ASTM E937/E937M.

2.1.6 Air Erosion

Dust removal shall not exceed 0.025 gram per square foot when tested in accordance with ASTM E859/E859M.

2.2 SEALER

Sealer shall be the type approved by the manufacturer of the fireproofing material, shall be fungus resistant, shall have a flame spread of 25 or less and a smoke developed rating of 50 or less when tested in accordance with ASTM E84, and shall be white color.

2.3 WATER

Water used for material mixing and surface preparation shall be potable.

PART 3 EXECUTION

3.1 SURFACE PREPARATION

Thoroughly clean surfaces to be fireproofed of dirt, grease, oil, paint, primers, loose rust, rolling lubricant, mill scale or other contaminants that will interfere with the proper bonding of the sprayed fireproofing to the substrate. Test painted/primed steel substrates in accordance with ASTM E736, with specified sprayed fireproofing material, to provide the required fire-resistance rating; painted or primed steel surfaces may require a fireproofing bond test to determine if the paint formulation will impair proper adhesion. Certify the acceptability of surfaces to receive sprayed-applied fireproofing by inspection and submit a Surface Preparation Report accordingly. The statement shall list the structural members and the areas that have been inspected and certified. Overhead areas to be fireproofed shall be cleared of all obstructions interfering with the uniform application of the spray-applied fireproofing. Hardware such as support sleeves, inserts, clips, hanger attachment devices and the like shall be installed prior to the application of the fireproofing. Condition of the surfaces shall be acceptable to the manufacturer prior to application of spray-applied fireproofing. Applications listed for use on primed surfaces shall be in accordance with the manufacturer's recommendations and standards, and detailed in submittal item SD-03 Product Data.

PROTECTION3.2

Cover surfaces not to receive spray-applied fireproofing to prevent contamination by splatter, rebound and overspray. Cover exterior openings in areas to receive spray-applied fireproofing prior to and during application of fireproofing with tarpaulins or other approved material.

Clean surfaces not to receive fireproofing of fireproofing and sealer.

FIREPROOFING MATERIAL3.3

Mix fireproofing material in accordance with the manufacturer's recommendations. Submit data identifying performance characteristics of fireproofing material. Data includes recommended application requirements and indicate thickness of fireproofing to be applied to achieve each required fire rating.

3.4 APPLICATION

3.4.1 Sequence

Prior to application of fireproofing on each floor, the manufacturer shall inspect and approve application equipment, water supply and pressure, and the application procedures. If fireproofing is required to be applied to underside of steel roof deck and steel floor assemblies, it shall be done only after respective roof or floor construction is complete. No roof or floor traffic shall be allowed during application. Fireproofing material shall be applied prior to the installation of ductwork, piping and conduits which would interfere with uniform application of the fireproofing.

3.4.2 Application Technique

Maintain water pressure and volume to manufacturer's recommendations throughout the fireproofing application. Apply fireproofing material to the thickness and density established for the specified fire resistance rating, in accordance with the procedure recommended by the manufacturer, and to a uniform density and texture. Do not tamp fireproofing material to achieve the desired density.

3.4.3 Sealer Application

If sealer is required by the product used, apply it after field testing has been conducted and after corrective measures and repairs, if required, have been completed.

3.4.4 Applied Thickness

The minimum average thickness shall be no less than 0.375 inches.

Thicknesses shall not be less than required to achieve designated fire resistance ratings. If the specified thickness is greater than or equal to 1 inch, any individual measurement shall not be less than the specified thickness minus 0.25 inches. If the specified thickness is less than 1 inch, any individual measurement shall not be less than the specified thickness minus 25 percent.

Application of Spray-Applied Intumescent Epoxy Coating System3.4.5

Prepare surfaces and apply the spray-applied Intumescent epoxy coating system in accordance with the manufacturer's written recommendations.

MANUFACTURER'S SERVICES3.5

3.5.1 General

The manufacturer, or its representative, shall be onsite prior to, periodically during, and at completion of the application, to provide the specified inspections and certifications; and to ensure that preparations are adequate and that the material is applied according to manufacturer's recommendations and the contract requirements.

3.5.2 Manufacturer's Inspection

The manufacturer shall inspect the fireproofing work after the work is completed on each floor or area, including testing, repair and clean-up, and shall certify that the work complies with the manufacturer's criteria and recommendations. Before the sprayed material is covered, and after all of the fireproofing work is completed, including repair, testing, and clean-up; and after mechanical, electrical and other work in contact with fireproofing material has been completed, the manufacturer shall re-inspect the work and certify that the entire project complies with the manufacturer's criteria and recommendations. Obtain and submit the Manufacturer's Inspection Report and certifications of approval stating that the spray-applied fireproofing in the entire project complies with the manufacturer's criteria and recommendations.

3.6 FIELD TESTS

The applied fireproofing shall be tested by an approved independent testing laboratory to be selected by the A/E and paid for by the Contractor.

Submit test reports documenting results of tests on the applied material in the project. Report shall include defects identified, repair procedures, and results of the retests when required. Perform the tests in approved locations: for density in accordance with ASTM E736, cohesion/adhesion in accordance with ASTM E736, and for thickness in accordance with ASTM E605/E605M. Determine densities in accordance with ASTM E605/E605M or Appendix A, "Alternate Method for Density Determination" of AWCI TM 12-A.

Take density determinations at the flat portion of deck, beam bottom flange, beam web, column, and an equivalent area from the top of the lower beam flange. Areas showing a density less than specified will be rejected. A test sample shall be located every 10,000 square feet of floor area or two for each floor, whichever produces the greatest number of test areas. Any area showing less than minimum requirements shall be corrected. Proposed corrective measures, in writing, shall be approved before starting the corrective action. Corrected work shall be retested.

3.6.1 Structural Components

Test each structural component type at floor and roof decks, beams, columns, joists, and trusses. Minimum average thickness shall be as required by UL Fire Resistance. Density and cohesion/adhesion shall be as specified.

3.6.2 Repair

Additional fireproofing material may be added to provide proper thickness.

Correct rejected areas of fireproofing to meet specified requirements by adding fireproofing material to provide the proper thickness, or by removing defects and respraying with new fireproofing material. Use same type of fireproofing material for repairs as originally applied or use patching materials recommended by the manufacturer. Retest and reinspect repaired areas. Apply fireproofing material to voids or damaged areas by hand-trowel, or by respraying.

Visual Inspections3.6.3

Inspections shall be made by the certified independent laboratory prior to closure of concealed areas. These inspections may be phased, but shall not occur less than 5 working days prior to the enclosure of the fireproofing.

Sprayed areas shall receive a final inspection. Fireproofed surfaces shall be inspected after mechanical, electrical, and other work in contact with fireproofing material has been completed and before sprayed material is covered. Any locations missing fireproofing shall be patched in accordance with the manufacturer's requirements.

3.6.4 Patching

Patch and repair damaged fireproofing. The patching material shall be the same as that specified for that area.

3.7 CLEANUP

Thoroughly clean surfaces not indicated to receive fireproofing of sprayed material within a 24 hour period after application.

-- End of Section --