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APPENDIX B – APPLICATION OF INTUMESCENT FIREPROOFING USING PITT-CHAR XP 1.0 Scope
This appendix covers requirements for material and application of intumescent fireproofing.
1.1 Blockout areas for field connection including bolt holes shall not be fireproofed in the shop but shall receive surface preparation and primer coat per this specification.
1.2
Blockout areas shall be kept to minimum. See structural steel drawings for the blockout details. 1.3 Installation details are shown in ATTACHMENT E.1.4 Top face of flange and top edges on beams supporting pipe and equipment shall not be fireproofed. The entire beam shall be blast cleaned per Section 7.2 and primed with SigmaCover 280 per Section 8.3. Top face including the edges shall be masked off during fireproofing application. All surfaces except top face and top edges shall be fireproofed with Pitt-Char XP per this specification. The top face and edges (Non-fireproofed surface) shall receive one coat of Amerlock 400 GF, 8-12 mils (200-300 mcrons) MDFT and top coat of ei ther Sigmadur 550 (gray) or Amercoat 450H, 2 to 3 mils (50 to 75 microns) MDFT. These coatings shall be applied after Pitt-Char XP application.
1.5 All horizontal finished surface of fireproofing such as column base plate, top face of bottom flange on beams, etc. shall have 50slope to prevent water ponding.
1.6 Fireproofing zone of galvanized columns shall be sweep blasted per Section 7.3 and primed with SigmaCover 280 per Section 8.3 prior to application of Pitt-Char XP.
1.7 Galvanized bolt on bolted connection shall be solvent wiped and surface shall be abraded with 80 grit sand paper, dust removed prior to application of SigmaCover 280 primer and finish off with Pitt-Char XP and approved top coat system. This application can be combined with fireproofing of field block outs.
2.0 Applicator’s Responsibility
Applicator QA/QC responsibiliti es as follows
a. Supply the equipment for the specified inspections and tests required for fireproofing activities.
b. Supply new and undamaged fireproofing materials received at the shop or field jobsite in the manufacturer’s original sealed containers.
c. Proper storage of all materials in the area protected from weather before and during application d. Inspection of fireproofing materials and accessories prior to commencement of work. Any material
that has been damaged or found to be defective shall be removed and replaced by the seller at his expense.
e. Inspection during key construction phase include, proper storage of materials, surface preparation, primer application, equipment setup and application (Pitt-Char XP), Installation of reinforcing mesh (Galvanized Steel), Pitt-Char XP thickness measurements and topcoat application.
f. Applicator shall ensure that the applicator conforms to latest QC Manual. This included (sample attached to this specification)
Pitt-Char XP Reference Smple
Pitt-Char XP Plural Equipment Daily Report Pitt-Char XP Daily Log
3.0 Manufacturer Responsibility
A technical service audit shall be conducted by the manufacturer during the initial start of fireproofing and provide technical assistance during production phase.
4.0 Submittals
4.1 Applicator shall submit to the buyer a list of materials to be used in fireproofing and shall identify the specific design mix including manufacturer’s datasheets and MSDS sheets.
4.2 Applicator shall submit written procedures for storage, handling, surface preparation, environmental control, application, verification of fireproofing thickness, repair, and inspection of the fireproofing. Procedures shall be submitted to Purchaser for review and approval prior to using them.
4.3 Subcontractor shall submit to Purchaser for review fireproofing verification forms as specified in clause 2.0 (f). Daily inspection forms shall be accessible for spot review on a daily basis.
4.4 Fireproofing verification forms shall be used to verify that proper materials were used, and that accepted application procedures and specifications were followed. Fireproofing verification forms shall include a statement of completion conformance.
5.0 Materials
5.1 General
Fireproofing materials shall conform to PPG Industries Pitt-Char XP Application Manual. 5.2 Primer
a. Primer shall be PPG SigmaCover 280.
b. Mid coat for top face of flange on beam PPG Amerlock 400GF c. Primer shall be approved and UL 1709 tested.
5.3 Pitt-Char XP 5.2
5.3
5.3.1 Fireproofing shall be Pitt-Char XP manufactured by PPG Industries Inc. 5.3.2 Pitt-Char XP shall meet the requirements of UL1709, per XR 612.
5.3.3 Fire rating of Pitt-Char XP shall be 2 hour per UL1709 in accordance with Pitt-Char XP Design XR 612
5.3.4 Pitt-Char XP shall have the following minimum physical properties: a. Dry density – 68 lb/ft3
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
c. Hardness – Shore D 35 when fully cured (determined in accordance with ASTM D2240)
d. Flame spread – Class A 15 (determined in accordance with ASTM E84)
e. Smoke developed – Class A 70-110 (determined in accordance with ASTM E84) f. Impact Strength – 1.46 ft. lbs/in (determined in accordance with ASTM D265 “A”) g. Adhesion strength to steel – 750 psi (determined in accordance with ISO 4624 for
film thickness <2mm, unreinforced))
Testing shall be performed to determine physical properties for above items a, b, c, f, and g. 1. 2. 3. 4. 5. 5.4 Reinforcing Mesh
1. Reinforcing mesh shall be galvanized steel hardware cloth ½” x ½” x 19 gage. 2. Reinforcing mesh shall be obtained locally or as required by applicator.
5.5 Topcoat
1. Topcoat shall be Sigmadur 550 (gray) or Amercoat 450H at 2-3 mils DFT. 2. Finish color shall be Medium Gray per RAL 7004.
6.0 Preconstruction Activities
6.1 Preconstruction Meeting
6.1.1 Project Engineer shall arrange for a preconstruction meeting with the following individuals in attendance:
a. Purchaser Project Engineer (primary project contact) b. Purchaser Non Metallic Technologist
c. Purchaser Lead Civil Engineer d. Purchaser QA/QC Inspector
e. Subcontractor representatives, including QC coordinator and foreman assigned to the job
f. Contractor structural steel fabrication/erection representative g. Manufacturer representative
6.1.2 Agenda to be covered at the preconstruction meeting shall include the following: a. Review of Contractor’s submittals and this specification
b. Inspection hold points
c. Controls of environmental conditions in the shop d. Condition of steel necessary to accept fireproofing e. Surface preparation and compatible primer application
f. Fireproofing application, installation of reinforcement, and thickness measurements g. Cure measurement prior to application of topcoat
h. Proper topcoat application
i. Exposure to elements only after system is completely sealed 6.2 Sample Preparation and Adhesion Testing
1. Applicator shall prepare a fireproofing sample on a 6 ft. long W10x49 carbon steel beam and two 6” x 6” x ¼” minimum carbon steel plates. The sample shall have pockets and tabs to represent complex shape. All samples shall be blasted, primed and top coated per project specification.
2. Sample requires inspection and approval in writing by the Purchaser before the Applicator proceeds with application of the fireproofing.
3. Sample shall illustrate correct fireproofing appearance, thickness, reinforcing, and surface finish, and shall be used as the application standard.
4. Carbon steel plate samples minimum 6” x 6” x ¼” shall be tested for adhesion in accordance with D4541 on unreinforced Pitt-Char XP only. Plates shall have surface preparation similar to beam with Pitt-Char XP applied to a maximum thickness of 2mm.
a. Adhesion of primer to steel or galvanizing shall be a minimum of 300 psi. b. Adhesion of fireproofing to primer shall be a minimum of 300 psi.
c. Adhesion of topcoat to fireproofing shall be a minimum of 300 psi.
5. Owner or his representative, Contractor, Subcontractor, and Manufacturer shall approve the sample.
6. Two random production pieces that are shop fireproofed shall also be tested for adhesion. 6.3 Area Inspection
Area that will receive fireproofing shall be inspected to verify that ducts, piping, equipment, or other items that would interfere with application of fireproofing are not positioned until fireproofing work is complete.
7. Substrate Inspection and Preparation 7.1 Inspection
1. Substrate shall be inspected to verify that it is ready to be cleaned/blasted.
2. Substrate shall be uniform and free of defects, such as weld deficiencies, lack of seal welding, and poor drainage of galvanizing.
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3. Any substrate defects that may adversely affect adhesion or performance of the fireproofing shall be properly repaired.
7.2 Non-Galvanized Substrate
1. Non-galvanized substrate shall be blasted in accordance with SSPC SP-10. 2. Blasted substrate shall have an anchor pattern of 2.0 to 3.0 mils minimum.
3. Specific abrasive shall be determined by the Applicator and approved by the Manufacturer prior to use.
7.3 Galvanized Substrate
1. Galvanized substrate shall be cleaned and degreased in accordance with SSPC SP-1. Alkaline cleaners shall not be used.
2. Cleaned substrate shall be blasted in accordance with SSPC SP-7/NACE No. 4. Abrasive shall conform to SSPC AB-1.
3. Blasted substrate shall have an anchor pattern that is sharp with no evidence of a polished surface.
8. Fireproofing Application
8.1 Ambient Considerations
1. Fireproofing shall be applied when:
a. Substrate temperature and ambient temperature are on the rise and greater than 50°F. b. Ambient temperature is 5°F above the dew point.
c. Relative humidity is less than 85%.
2. Areas where fireproofing is applied shall be ventilated for 24 hours after application. 3. Work area shall be kept clean and well ventilated.
4. Spillage and over-spray shall be removed promptly before material has cured. 8.2 Protection of Adjacent Areas
1. Adjacent equipment and surfaces that will not be fireproofed shall be protected from damage by over-spray, fall-out, or dusting.
2. Ducts in areas where fireproofing is being applied shall be closed and sealed. 8.3 Primer Application
1. Primer shall be applied to a dry film thickness (DFT) of 2 to 3 mils. Maximum allowable DFT on overlaps shall be 3 mils.
2. For non-galvanized substrate, primer shall completely cover the blast profile.
3. Prior to application of primer, on galvanized substrate, excessive zinc thickness may be reduced by sanding with P80-P-100 grade aluminum oxide abrasive paper for small areas.
Polishing shall be avoided. For large surfaces, galvanized surface shall be sweep blasted per SSPC-SP7
8.4 PITT-CHAR XP Mixing
1. Properly mixed PITT-CHAR XP is a medium gray (with no striping).
2. A quality control check for mixing shall be a ratio check, performed by the Subcontractor. The ratio check shall be by weight as follows:
a. Weigh clean empty Parts A and B containers and note the respective weight.
b. Place the container under the ratio check valves located on the mixing block and open the valve at exactly the same time under 2000 psi pump pressure or as required to give a slow steady flow.
c. Close the valves when the containers are at least half full at exactly the same time. d. Calculate the ratio of Part A and Part B as a percentage of the total weight. Example
Part A to Part B ratio is 3.25:1. Acceptable range is from 2.93 to 3.58:1.
3. A minimum of two ratio checks shall be performed per shift, (1) start of the shift and (2) when the pump is shut down and restarted.
8.5 PITT-CHAR XP Application
1. Primer shall be allowed to cure for a minimum of twelve hours at 77°F before the PITT- CHAR XP is applied.
2. Before PITT-CHAR XP is applied, primed substrate shall be cleaned of dirt, dust, grease, oil, loose material, or other matter that may adversely affect PITT-CHAR XP bond.
3. PITT-CHAR XP shall be applied in accordance with PITT-CHAR XP project Manual.
4. PITT-CHAR XP materials shall be kept within a temperature range of 86°-93°F for 24 hours prior to use with a plural pump with heated holding tank.
5. PITT-CHAR XP shall be applied using plural component spray equipment from PPG approved suppliers; Spray Quip Inc., Spraypump, Airtech or Covercat.
6. Operating parameters for plural component spray equipment shall be in accordance with current Project Application Manual.
7. PITT-CHAR XP shall be applied to a minimum thickness of 13.2 mm per UL Design XR 612 for 2 hour rating (UL 1709 certification directory).
a. Minimum thickness at any one point shall not be less than 85% of specified thickness. b. Overall average thickness shall be equal to, or greater than, the UL specified thickness. c. UL certified thickness is based on the average thickness.
8.6 Reinforcing Mesh Application
1. Reinforcing mesh shall be cut and bent to fit the flange thickness plus 5-6mm coating applied and cured (1 coat) before the Pitt-Char XP is applied.
2. Mesh sections shall be cut from a roll 2, 3 or 4 foot wide and bent on a 4 ft wide minimum brake to ensure straight crisp bends. The ½ x ½ x 19 gage galvanizes steel mesh shall be
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bent to fit 2-4 inches from flange edge toward the web in a “U” shape per attached drawing. The bent mesh sections will be attached using a friction fit method on full flanges.
3. 3 sided beams shall have the inner top flange meshed by laying the uncoated flange facing down, fireproofing the 3 sides and lying in the flat mesh sections onto the first coat of Pitt- Char XP before cure. An option for pre erected 3 sided steel beams is to attach weld pins 2mm diameter x 25-50mm long in two rows 300mm centers on each half flange face to secure the mesh in an inverted position after the first coat of Pitt-Char XP has cured by bending the pins over the mesh to secure.
4. Adjacent pieces of steel mesh shall be butt joined at seams with a 25mm maximum gap. 5. Mesh shall be installed after approximately 5-6mm of Pitt-Char XP has been applied. 6. Second coat of Pitt-Char XP shall be troweled or rolled into mesh to ensure complete
encapsulation with no voids or mesh edges protruding from the coating. 8.7 Topcoat Application
1. Topcoat of either Sigmadur 550 or Amercoat 450H shall be applied per PPG recommendation.
2. Unless otherwise specified, topcoat shall be applied within seven days after the PITT-CHAR XP is applied. If the seven days are exceeded, the surface of the PITT-CHAR XP shall be sweep blasted or mechanically abraded with 40 grit paper (or equivalent) and solvent cleaned prior to applying the topcoat.
3. Topcoat shall be applied to a minimum DFT of 2 to 3 mils. 9. Inspection, Testing, and Repair
9.1 Daily Production Samples and Tests
1. Daily production samples shall be taken one per shift. Additional samples shall be taken if material batch numbers change. This can be accomplished by spraying material into a plastic cup and identifying sample number and date.
a. Samples shall be tested randomly to determine fireproofing hardness and density properties.
b. Sample shall be documented on the PITT-CHAR XP Fireproofing Daily Log. 2. The following inspections and tests shall be performed on a daily basis.
a. Degreasing stage – surface contamination – Visual, white cloth check for oils or other harmful contaminates [SOVENT WIPE TEST]
b. Blast cleaning – Visual inspection to ensure sheen surfaces are dulled by sweep blasting steel [VISUAL]
c. Primer – Wet film thickness measurements primer [WET FILM GAGE]
d. Inspect spray equipment – Operating conditions of plural component equipment [MATERIAL RATIO WEIGHT CHECK]
e. Application of PITT-CHAR XP – Inspect wet film thickness with approved wet film probe [Bridge Gage], observe mesh installation
f. PITT-CHAR XP dry film gage [Elcometer or similar] capable of measurements for the specified Pitt-Char XP thickness and a calibrated probe such as a digital caliper to be inserted in a predrilled 1/8” hole or as required to measure steel meshed areas.
g. Inspect cure of PITT-CHAR XP – [DUROMETER SHORE D]
h. Topcoat – Inspect application of topcoat [WET FILM THICKNESS / visual after cure)] i. Environmental test equipment – Sling pychrometer, surface thermometer
9.2 Deficiency Inspection and Repair
1. Deficiencies in the fireproofing shall be inspected, noted, and properly repaired. Deficiencies include, but are not limited to, the following:
a. Cracks or seams of any length in PITT-CHAR XP. b. Disbondment of primer, PITT-CHAR XP, or topcoat c. Exposed reinforcing mesh
d. Inadequate fireproofing thickness.
e. Excessive mills and subsequent coating runs, drips, spills, and curtains.
2. Repair of deficiencies shall conform to procedures as stated in the project Pitt-Char XP Manual. If necessary, manufacturer shall write a repair procedure not cover in the Manual. 3. A written repair procedure shall be submitted to the Purchaser before repairs are performed. 9.3 Hardness Test
1. PITT-CHAR XP shall have a minimum Shore D value 24 hours after PITT-CHAR XP application of 25 and >35 before application of the topcoat.
2. Shore D Hardness test shall be performed using a Shore D gauge. 3. PITT-CHAR XP shall have a fully cured Shore D value greater than 35. 4. Hardness readings shall be taken on areas that are relatively smooth. 5. Ten readings shall be taken per area, discarding the low and high reading. 9.4 Density Test
1. Random daily production samples (see 8.1) of PITT-CHAR XP shall be tested for density a minimum of once per week.
2. PITT-CHAR XP shall have a minimum density of 68.7 lbs./ft
3
. 9.5 Final Inspection
Final inspection of the installed fireproofing shall be performed jointly by the Applicator and the Purchaser.
9.6 Test Results
Test results shall be recorded on “PITT-CHAR XP Customer / Application Quality Control Report” and the “Fireproofing Daily log”.
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10. Curing
Fireproofed surfaces shall not be exposed to the exterior elements until the fireproofing is completely cured and the topcoat is properly sealed over the entire fireproofed surface.
11. Shipping and Handling
All fireproofed steel shall be handled using nylon slings or other approved lifting methods. Proper dunnage during transport, storage and jobsite erection shall be used to minimize damage to the fireproofing. Large heavy steel sections should be lifted with sling on block out areas or lifting points to avoid edge damage to fireproofing.