COMPARTMENT
BARRIERS

Concrete Protection from Hydrocarbon Fire Exposure

FRL240/240/240

PROTECTING CONCRETE STRUCTURES WHEN EXPOSED TO THE HYDROCARBON FIRE CURVE

TBA Firefly Intubatt® Protecting Road/Rail Tunnels & Petrochemical Plants with DTS Tested Systems for Concrete Walls/Floors & Ceilings FRL 240/240/240

Patent Pending

Minimum 100mm thick of Concrete Floor/Ceiling or Wall which has been designed to carry the applied loading @ ambient temperatures in accordance with AS3600:2018.

FLOOR/CEILING

DTS FRL240/240/240

1 layer of 50mm thick TBA Firefly™ Intubatt® fixed to the underside: Total System thickness 150mm

WALL (1 Way Fire)

1 layer of 50mm thick TBA Firefly™ Intubatt® fixed to the Fire Side Face: Total System thickness 150mm.

DTS FRL240/240/240

 

WALL (2 Way Fire)

1 layer of 50mm thick TBA Firefly™ Intubatt® fixed to the Both Faces: Total System thickness 200mm

DTS FRL240/240/240

 

DTS System FRL240/240/240 Tested in accordance with AS1530.4-2014 & Assessed in accordance with AS4072.1-2005

Warringtonfire Report No: FAS210258 RIR

This is a Report from an Accredited Testing Laboratory which meets Specification A2.3 Section 2 (c) of NCC2016 Amendment 1 (Including Prior Versions) & Schedule 5 Section 2 (c) of NCC2019 (Including Amendment 1) for determination of an FRL.

The Hydrocarbon Fire Curve is significantly more onerous than that of the standard Cellulosic Fire Curve, especially for concrete due to the rapid heat rise over a very short period of time. This rapid heat rise creates a number of thermal shocks which would generally cause spalling of the concrete within a very short time period of exposure.

Complete Concrete Protection Zero Spalling witnessed during or after the Test

NEW BUILD

Benefits of the TBA Firefly™ Intubatt® Concrete Protection DTS Tested System:

  • Equivalent concrete thickness (ε) for concrete slab. One layer of 50mm thick TBA Firefly™ Intubatt® is equivalent to 142.5mm thick of concrete @ 4hours of Hydrocarbon Fire Curve Exposure.
  • 100mm thick of concrete is approximately 240kg/m2. (142.5mm thick = 342kg/m2)
  • 1 layer of 50mm thick TBA Firefly™ Intubatt® is approximately 9kg/m2.
  • Potential weight reduction of 333kg/m2
  • The structural steel/concrete vertical support between each floor level won’t have to be as strong as they have less of a load to carry
  • Concrete Carbon Footprint Reduction: The manufacture of cement produces about 0.9 pounds of CO2 for every pound of cement. Since cement is only a fraction of the constituents in concrete, manufacturing a cubic yard of concrete (about 3900 lbs) is responsible for emitting about 400 lbs of CO2. (Source: The Portland Cement Association)

RETROFIT CONCRETE FIRE UPGRADES

Current Potential Issues for some building stock in Australia:

  • Concrete Flat Slab is less than 200mm thick
  • Alternate Solution (FES) which states that the concrete slab achieves an FRP90/90/90 or FRP120/120/120 when determined in accordance with AS3600

We believe that this may be a serious non-compliance issue, due to the fact that Table 5.5.2(A) is sometimes overlooked in some Fire Engineered Solutions. This means that an FRP90/90/90 or FRP120/120/120 cannot be determined within an Alternate Solution (FES) in accordance with AS3600 if the floor slab is less than 200mm thick. Therefore the only route to compliance is via a DTS Tested System FRL.

The same applies for where the slab may be 200mm thick and designed for a building which originally only required an FRP90/90/90 or FRP120/120/120 or FRL90/90/90 or FRL120/120/120 which has since had a change of use and the FRP or FRL needs to be higher.

Solution:

Minimum 100mm thick Concrete designed to carry the applied loading @ ambient temperatures:

Install one layer of TBA Firefly™ Intubatt® to the underside of the slab to achieve a DTS FRL240/240/240 Horizontal separation Protection

Install one layer of TBA Firefly™ Intubatt® to one side of a concrete wall to achieve a DTS FRL240/240/240 Vertical Separation (1 way) Protection

Install one layer of TBA Firefly™ Intubatt® to both sides of a concrete wall to achieve a DTS FRL240/240/240 Vertical Separation (2 way) Protection

GROUP NUMBERS

If a Group Number is required for your application, the TBA Firefly Intubatt® is overlayed with TBA Firefly™ EKA-161 Non-combustible Sarking (Non-Breathable)

TEST METHOD AS ISO 9705-2003 (R2016)

Warringtonfire Reaction to Fire Test Report Number: RTF210386

RESULTS

ROOM CORNER BURN PRIOR TO TEST IMAGE

 

ROOM CORNER BURN DURING TEST IMAGE

 

ROOM CORNER BURN DURING TEST IMAGE

 

ROOM CORNER BURN POST TEST IMAGE