1.0 PURPOSE.
2.0 SCOPE.
3.0 REFERENCE DOCUMENTS.
4.0 RESPONSIBILITIES.
5.0 GENERAL.
6.0 INSTALLATION PROCEDURE .
7.0 REPAIR PROCEDURE.
8.0 INSPECTION AND QA/QC PLAN.
9.0 SAFETY ASPECT .
10.0 ATTACHMENT.
1 PURPOSE
This method statement defines the procedure to be adopted for the construction of Fireproofing Work in respect of commercial buildings, plants and refineries. Fire proofing is one of the options available to mitigate damage caused by fire. It offers protection against the adverse thermal effects of fire for a limited period and limited degree of exposure. It should not be considered as a replacement for active fire fighting.
Main objective of fireproofing of steel support and structure is to prevent the escalation of fires to an unacceptable level by providing a protection for a limited period of time (two hours minimum) until full fire-fighting capabilities can be deployed. A sudden collapse of supporting steel structures could result in release of large quantities of flammable products or toxic materials, leading to effects which might extend beyond the property limit.
Judicious application of fireproofing will delay an eventual collapse of steel structure and allow it to occur gradually and with visible signs. This allows time for isolation of the affected equipment and fire fighting personnel to evacuate safely.
2 FIREPROOFING WORK PROCEDURE FOR STRUTURES | METHOD STATEMENT
This procedure describes the activities of Fireproofing works and such as Steel structures and Vessel skirts of Jazan Refinery and Terminal project.
3 REFERENCE DOCUMENTS
U-L 1709 : Rapid Rise Fire Test.
BS 476 Part 20 : 1987 Appendix 0 (Hydrocarbon Curve).
SAES-B-006 : Fireproofing for Plant.
SAES-H-101 : Approved protective coatings ystems for Industrial plants and Equipment.
4. RESPONSIBILITIES
4.1 The Construction Manager shall have responsibility for overall implementation of all HSE requirements on site and authority for direction and control of the fireproofing work including all necessary provisions to perform the activities
4.2 The Technical Supervisor in the Construction Team shall perform the all activities and shall provide all inspection and control required for the execution of fireproofing work.
4.3 Inspection shall be performed by the QC Inspector and/or at the presence of Company.
4.4 Safety Officer shall have responsibility and authority for checking the hazardous points and instructing technical supervisor for safe working conditions and supervising during the erection of equipments at site.
5. GENERAL
5.1 Introduction
Fendolite MII is suitable for on or off site application to structures, pre-assembled units (PAUs), pipe racks (PARs) , equipments and single steel members. Structures protected with Fendolite MII have been fully tested and assessed for up to 4 hours fire resistance in accordance with BS 476, Part 20: 1987 Appendix 0 (Hydrocarbon Curve) in the UK and UL 1709 in the USA.
FENDOLITE MII DATA
General : Single Package, Water added on site
Colour : Off-White
Cure : By hydraulic set
Flash Point : None
Minimum Density (Dry in Place) : 680kg/m³
Theoretical Coverage (@ Dry in place Density of 775kg/m3) : 1.55m³ /tonne
Bonding Strength : 11,000psf
Approximate Curing Time @ 20 °C 50% RH
Initial Set : 2 – 6 hours
Subsequent coats After initial set
50% Strength 5 days
75% Strength 12 days
98% Strength 28 days
PH Value 12 – 12.5
Thermal Conductivity 0.19W/ °C @ 20 °C
Storage Off the ground and kept dry until ready for use
Shelf Life 12 months maximum
Packaging 20kg bags
5.2 General Guidance
5.2.1 Material Storage
Bagged Material
These materials must be kept dry until ready for use. They should be stored off the ground, undercover and away from wet or damp surfaces or areas of very high humidity Storage temperatures are not critical as long as dry conditions are maintained. They can be stored up to 12 months from date of shipment under good, dry conditions.
Water Based Coatings
These products shall be protected from frost and should not be stored in high ambient temperatures or in direct radiant sunlight.
5.2.2 Site Application Requirements
The applicator should ensure that adequate services are available on site such as, suitable electrical supply, compressed air, clean water should be odorless and colorless, and waste disposal facilities.
Cold Wet Conditions
The material should not be applied unless the substrate and air temperature is at least 2 oC and rising or if the substrate and air temperature is less than 4
oC and falling. The surface should be dry and its temperature should be at least 2 o C above dew point temperature.
The following factors may assist application in cold weather.
• Warm mixing water may be used.
• Shielding the work area from cooling winds.
• Using a heated enclosure. Care should be taken to prevent excessive evaporation of water.
Hot, Dry Conditions
In very hot, dry conditions, particularly where strong radiant sunlight or strong winds or both are a feature, it is necessary to protect Fendolite MII from too rapid evaporation of its moisture. This can be achieved by: –
• Screening the work area from radiant sunlight/drying winds.
• Wrapping exposed members tightly after application of Fendolite MII with polythene sheeting to retain moisture which will require periodic wetting down.
• Cooling the steel surface prior to application with clean water.
Drying
Provision should be made for adequate ventilation during and after application until the coatings are dry.
Masking
In some cases it may be necessary to mask off surrounding areas to protect from overspray.
5.2.3 Equipment
Equipment for the Application of Fendolite MII
• A spraying machine based on a metal rotor/flexible stator e.g. mono pump is recommended. Normal pump speed is in the range of 100 – 600 rpm.
• A mechanical mixer e.g. paddle blade or drum type concrete mixer should be used. Minimum capacity is 150/100 liters (5/3 1/2 cu ft).
Rotational speed 20 – 30 rpm under load, maximum 35 rpm for free running.
Small capacity mixers and mixers with too high a rotational speed should not be used as they are detrimental to Fendolite MII.
• An air compressor of adequate capacity is required. This may form an integral part of the spray machine or stand alone as a separate unit.
A capacity of 0.42 m² per minute (15cfm) free air delivery (FAD) and a pressure of 3.5kgf/cm² (50 lbf/in² ) are normally suitable at the spray head.
In cases where an air driven spray machine is utilized then reference should be made to the manufacturer to determine the necessary air capacity required to drive the equipment.
6 INSTALLATION PROCEDURE
6.1 Substrate Preparation
New Primed Steelwork
It is the responsibility of the applicator to ensure that all substrates to be protected are in a suitable condition to accept the coating.
All steel substrates to be protected from the effects of fire in petrochemical plants and refineries are normally either galvanized or primed and painted to provide long term corrosion protection from aggressive exterior atmospheres.
Whilst these epoxy coated (and galvanized) surfaces are chemically compatible with Fendolite MII.
Old or Existing Steel Substrates
Fendolite MII may occasionally need to be applied over either old/existing-primed steel or over
primed and painted steelwork in unsound/poor condition.
Vessel skirts and saddle supports
Vessel skirts and saddle supports may be considered as structural elements.
6.2 Surface Preparation
Surfaces to be coated must be free from oil, grease and visible moisture (including condensation), dirt, loose paint, dust, loose mill scale or other materials. Approved touch-up paint should be applied after pin-fixing.
6.3 Mesh Reinforcement/Retention
Reinforcing Mesh
Hexagonal reinforcing mesh is required on steel beams or columns when Fendolite MII is to be applied by either ‘following the profile’ or ‘solid fill’ methods of application. The reinforcing mesh must be positioned so as to lie substantially within the mid third of the applied Fendolite MII thickness.
Mesh Types
• Plastic coated wire mesh of size 50mm x 50mm x 1.2mm (minimum thickness).
Recommended Fixings
• Coppered steel stud pins 2mm diameter x 30mm long with galvanized steel clip (30mm x 30mm).
6.3.1 Installation
Steel sections up to and including 203mm x 203mm are normally protected by the solid fill method.
Steel sections greater than 203mm x 203mm are normally protected by the profile method. Pins are attached to substrate at maximum 400mm on a staggered pitch.
General Notes
• Mesh must be overlapped by at least 50mm at all joins. No more than 3 layers should overlap at any one point.
• For thickness of spray up to 45mm the mesh may be applied prior to application. It is important that the mesh is not hard up against the substrate, therefore once secured by clips or helical pins, the mesh should be pulled away from the substrate so as to lie substantially in the middle third of the thickness being applied.
• Where the thickness exceeds 45mm the mesh may be fixed to a suitable length pin after application of approximately half the Fendolite MII thickness.
• It is essential that the mesh is positioned away from the substrate by approximately 6mm using suitable spacers.
6.4 Mixing Procedure of Fendolite MII
Fendolite MII products are factory-controlled premixes, which only require the addition of clean water on site to produce a mix of suitable consistency.
Fendolite MII requires 15 ~ 19 liters/20kg bag.
Prior to the application of any of the materials, the following points should be noted: –
• Sufficient material should be conveniently placed by the pump and mixing equipment to ensure continuity of supply.
• Pump and mixing equipment should be clean and operational and should be positioned to optimize the spray area available.
• Prior to application, substrate and air temperature reading should be taken and recorded where relevant, as the products may suffer permanent damage if: –
– They are frozen before they are cured sufficiently to resist disruption by freezing
or
– Their cure is affected by rapid migration of moisture due to excessive heat.
• Any masking for the protection of sensitive areas should be carried out prior to commencement of application.
• Ensure that the surfaces to be protected are in a suitable condition.
• Make sure that the mixer and all tools are clean.
• Ensure that mixing water is clean quality (odorless and colorless).
• Place most of the required mixing water into the mixer.
• Partially set, frozen or lump material must be rejected.
• Add the tagged material steadily. Add the remainder of the mixing water slowly until a suitable consistency is obtained.
• Mixing time is 3 minutes to ensure correct properties of the mix. It is important not to add more water than is required to obtain an easily pumpable or trowellable mix. As a general rule, do not deviate from the recommended quantities of water.
• Provided that mixing is almost continuous, the next batch can be prepared without washing out the mixer. The measured mixing water should be poured into the mixer so that it washes the remains of the previous mix from the walls of the mixer.
• Where a pump has not received a continuous supply of material e.g., morning start up, clean water should be passed through the pump, hose and spray head. When the mixed materials is introduced into the pump sufficient material should be allowed to pass through the spray head to ensure that all traces of surplus pre-delivery water are removed and the correct mix consistency is reached.
• The length of time the material will remain workable will depend on the ambient conditions. However, as a guide and based on an ambient temperature of 20 oC and relative humidity of 50%, Fendolite MII can remain workable up to 1 hour.
• If the mixer is to be left for an extended period of time, then it should be thoroughly cleaned with water and left ready for further use.
• Additional water must not be added to regain workability. Unworkable material must be rejected. Any partially set material left in the mixer must be cleaned out before further batches are mixed.
6.5 Application Procedure – Fendolite MII
• Fendolite MII should be sprayed to give an even coating over the background building up in a series of passes. Even coats are obtained with steady sweeps of the spray head that is held at 90 degree wherever possible, but not held stationary.
• The correct amount of air introduced at the nozzle is essential to ensure consistency of texture and correct density of material usually 2.1 ~ 3.5 kg f/cm² (30 ~ 50 psi).
• Coating thicknesses should be continuously checked to ensure that the correct thickness is applied.
• Where structures include a horizontal surface that requires coating on the top-side (e.g. top of the bottom flange of a beam) the first spray pass should be made on to that surface. This will avoid the possibility of reduced bond strength resulting from application onto loose over spray which can sometimes occur from prior applications to the other surfaces.
• When applying the materials to columns it is important that the coating thickness around the flange edges is the same as the thickness on the remainder of the section. Failure to observe this means that the full fire rating may not be obtained.
• For situations where the materials are applied in more than one coat, the preceding coat should be left with a spray texture finish or well scratched to ensure good bonding of subsequent coats.
• The time between coats will be subject to the environmental conditions at the time of application.
• If the surface has become very dry, it should be well dampened with clean water before applying further coats, but must not exhibit a water sheen. Ideally subsequent coats, if required, should be applied within 48 hours of initial set of preceding coat.
6.6 Surface Finish and Thickness Tolerance
• It is recommended that Fendolite MII products are trowel finished once the specified thickness has been applied and allowed to brush smoothly.
• The recommended thickness tolerance that should be achieved on site is 0 ~ +3 mm. Individual specifications may require other tolerances and should be followed if appropriate.
6.7 Top coating
• Top coating is a water permeable topcoat which may be applied once the Fendolite MII has dried or shown a color change by airless spray or roller in two coats to a WFT of 150-200 microns.
7. REPAIR PROCEDURE
Damaged Fendolite MII may be repaired by either a further spray application of Fendolite MII. The repair procedure should be carried out as follows: –
• Cut away any loose Fendolite MII, chamfering any sharp edges. Where mesh reinforcement is exposed, clear the Fendolite MII away from the mesh and ensure that it will remain in the mid third of the repair. If damage has resulted in mesh failure, totally remove the affected mesh and reinstate with new mesh ensuring that a minimum 50mm overlap onto the original mesh is achieved and that it is secured by the use of wire ties or twisting cut ends together. Ensure correct mesh position.
• Remove loose dust.
• If existing Fendolite MII has become very dry, dampen the surface adjacent to the repair site with clean water.
• Mix the Fendolite MII in accordance with the mixing procedure.
• Apply Fendolite MII and finish level with existing material.
• If more than one coat is required ensure that preceding coats are left with a rough finish or
in the case of Fendolite MII well scratched to ensure good bonding of subsequent coats.
• When patch is dry, reinstate any previously applied surface treatment.
8. INSPECTION AND QA/QC PLAN
Please refer to the attached sheets.
INSPECTION
Substrate Inspection
Check that the substrate is in a suitable condition before proceeding. It should be dry and free from oil, grease, dirt, dust, scale.
Pin fixing (where required)
The fixed pin areas shall be inspected for:-
Correct grinding of surface to bright metal.
Correct type, spacing (400mm maximum) and fixing of pins, including a 45 degree bend test for straight pins. Maximum allowable failure rate are not more than 15%.
Mesh type and Fitting:
Plastic coated wire mesh: size 50mm x 50mm x 1.2mm (minimum thickness). Check the fitting of retention mesh, ensure that clip, if required, are fitted correctly and that overlaps between sections of mesh are to specification. Prior to commencement of spraying, the mesh should be checked to ensure it is pulled away from the substrate to lie substantially in the middle third of the final coating thickness. The effectiveness of the entire retention system is negated if mesh is left hard against the substrate.
Density Measurement and Slump Test
Density Measurement
During normal spraying operation, take a daily sample of material from both the mixer and spray nozzle working in the normal mode. The samples should be taken in a standard container of known volume (without the use of agitation to increase packing rate). Using the edge of a trowel or a tensioned wire, level the top of the sample by cutting back immediately after spraying or sampling from the mixer.
Slump Test
As mix is being discharged into hopper, fill the plastic tube (pre-placed on flat plate) with mix and cut back to level off the top. (Do not agitate or compress the sample into the tube.) Raise tube slowly and carefully vertically until the sample has slumped back out into the plate. Place the tube upright on the template adjacent to the slumped material. Using the straight edge and 150mm rule measure and record the vertical distance from the top of the tube to the top of the concave depression at the top of slumped material. Place slumped material into plastic bag. Weigh bag plus sample and record the result.
Note: The plastic tube has a volume of 1 liter; therefore weight of the sample in grams taken from above procedure will represent density in grams per liter which is numerically the same as density in kg/cu.m.
Result: The value obtained by following the foregoing procedure should lie within the following ranges:-
Density from mixer discharge 690 – 840 kg/m³.
Density at sprayhead 1070 – 1310 kg/m³.
Slump 40 – 55 mm
Surface Finish and Water Shedding
It is recommended that Fendolite MII is trowel finished using typical plasterer’s tools once the specified thickness has been applied and allowed to brush smoothly. Check that where there is a risk of water accumulating on a Fendolite MII protected surface it has been sloped to reject water. This is particularly important on beams where the top surface of the bottom flange when following the profile of a beam.
Thickness Control
When each surface to be protected is required to have the same thickness of 34mm, as in the case of steel “I” section column and beams, at least one thickness measurement every 3 meters should be taken on each surface of the flange and the web. On steel “I” sections, the spray coating on the flange should not be permitted to taper off toward the flange edge. Where it appears as tapering, the thickness should be checked across the flange and over the flange edges at the recommended nominal 3 meter intervals.
The specified thickness is a minimum requirement; however, minor thickness variations may occur. The recommended thickness tolerance that should be achieved on site is -0+3 mm unless the contract or clients own specification dictates otherwise.
Completed Area
Completed areas should be checked by the client with the application in attendance and passed in writing as acceptable before the applicator vacates the area.
9. SAFETY ASPECT
9.1 Unusual and unexpected acute hazards maybe encountered during the fire proofing work.
9.2 All personnel those who will be involve in this job shall be oriented with the nature of the job and the hazard that maybe encountered.
9.3 All the personnel involving in the job shall wear the following PPE (goggles, helmet, full coverall, dust proof mask)
9.4 Working at height, while doing this job above 1.5m height from ground level the safety full body harness is mandatory and same to be tied-off all the time
9.5 First aid box is mandatory at the work site, this shall controlled by first aider.
9.6 During the application of materials, the safety information recommended by the manufacturer shall be followed in addition to normal PPE’s whenever and wherever required.
9.7 The work permit shall be kept available on the work area along with JSA in which the hazards are explain in detail.
10. ATTACHMENT
10.1 Density Check Report
10.2 Inspection Report
10.3 Job Safery Analsis