phone: 586.576.7600 fax: 586.576.0850...
TRANSCRIPT
2
……………………………. .3
…………………………….3
………………...….4
………….5
……………………………...7
…………...…………….….9
……………………………...12
…….......14
………..……….15
© COPYRIGHT 2009-2010 Firespray International Ltd. All Rights Reserved; Revision 2.0
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 2009. 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.
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 2002. 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.
5
ASTM E-2336: Fire Resistive Grease Duct Enclosure
Systems
Complies, Listed by Intertek ETL
Zero clearance to combustibles at all locations on duct
wrap’s surface
ASTM E-84 / UL723: Surface Burning Characteristics
- Flame Spread Rating
- Smoke Developed Rating
Unfaced Blanket Encapsulated
Zero <25
Zero <50
ASTM E-814: Firestop Test
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
ASTM E-136: Non Combustibility Test
Complies
ASTM C-518: Durability Test
Complies
UL 1978: Test Standard for Grease Ducts
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-2336. 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
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 semi-
exposed 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 0.016 in per in
At 1112°F an expansion of 0.008 in per in
At 806°F an expansion of 0.006 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:
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, 2nd
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 0.03” - 0.04” 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.
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
Figure 1: Duct Reinforcement
8
Figure 2: Steel Angle (RSA) Flanged Joint
Figure 3: Ductmate Flange with G-Clamp
Figure 5: Duct Seam Figure 6: Ductmate Flange
with Gasket
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).
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.
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
Figure 4: Duct Seam
9
Table 2: Grease Duct Support Details
Figure 8: Duct Segment Repair
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.
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.
10
Figure 9: Supports for Risers
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.
11
Figure 10: Penetration Seals
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.
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 (www.ul.com, UL Category: XHEZ)
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,
www.unifrax.com.
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
Duct
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
14
Fig
ure
13:
Fir
espra
y S
TD
38
0
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
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
3114842. 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.
17
PART 2 PRODUCTS
2.01 Manufacturer of Flamebar BW11 Coating and Ancillaries
A. Approved Manufacturer: Firespray International, 101 Tiffany Dr, Waynesboro,
VA 22980. Tel: (972) 365-5302. www.FiresprayUSA.com
1. 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) 365-5302 or
[email protected] for a current listing of Flamebar Licensees in North
America.
2.02 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.
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.
2.03 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.
3.02 Installation of Ductwork
Install in accordance with the relevant Firespray construction standard and any applicable
local codes.
© COPYRIGHT 2009-2010 Firespray International Ltd. All Rights Reserved
Revision 2.0