INDUSTRIAL FIREPROOFING

Fire proofing are of two types. Active Fire proofing (AFP) and Passive Fire Proofing (PFP).

Active Fire Proofing (AFP) means fire proofing using fire extinguisher, sprinkler, form, Co2 etc. which is done to extinguish fire when it is on. That means this method requires a triggering in order to be effective.

Passive Fire Proofing (PFP) on the other hand is to extend the time for failure/collapse of structure, equipment etc. so that the personnel can escape to safe places when they are exposed to fire. Fireproofing using Passive Fire Protection (PFP) method is the most used method of industrial fire proofing.

The level of protection required is dependent on the size, mass and configuration of the steel section. These systems are used to prevent steel structures from reaching the temperatures at which the structure will begin to fail. This is known as limiting temperature. Normally, the lower the limiting temperature required for a structure, the higher the thickness requirements will be to protect that structure.

Fireproofing systems are applied along with a corrosion resistant primer to provide fire protection as well as corrosion resistance.

Fireproofing materials are selected considering operating conditions, types of exposure, substrate, environmental regulations, application conditions, cost, time constraints and design/fabrication considerations.

Fire rating of the coating will tell us the required thickness of the coating required to withstand a time period, when exposed to fire. FRR is mentioned for 3 things stability, integrity and insulation. FRR30 means 30 minutes the item can withstand fire.

PFP can be divided in to three basic types

a. Dense Concrete

b. Cementitious fireproofing

c. Epoxy intumescent fireproofing

Dense Concrete

Dense concrete is also used as the fire protection material. But they adds more weight and chances of crack during transportation and handling as compared to cementitious and epoxy intumescent fireproofing material.

Cementitious Fireproofing

This is a cement based fireproofing material that provides fire protection through its inherent insulative properties. The protection depends on the thickness of the fire proofing material

Epoxy intumescent Fireproofing

Epoxy intumescent fireproofing has the appearance and application characteristics of a protective paint or coating. Under the extreme temperatures of fire, they activate and intumesce to produce a char layer that provides thermal protection for the steel.

Under normal conditions these coatings are inert or "passive" like other paint-like coatings. When exposed to the extreme heat of fire, these coatings begin to intumesce or expand, forming a thick heat blocking char layer. This heat blocking char provides an insulating layer that protects the steel from reaching the critical failure temperature for a given amount of time.

Testing Standards

One of the main requirements that every fire proofing material requires is Underwriter's Laboratories (UL) certification of the product. The UL certified product is traceable in www.ul.com.

Two main hydrocarbon test standards that are commonly used in many parts of the world are

1. UL 1709, "Rapid Rise Fire Tests of Protection Materials for Structural Steel"

2. ISO 834/BS-476 Hydrocarbon fire curve.

The main two tests that are conducted on PFP materials are

1. Hydrocarbon pool fire

2. Jet fire exposures

Other tests are

1. Explosion testing

2. Hose Stream Testing

3. Cryogenic Testing

INSTALLATION

1. The storage of materials of PFP shall be as per vendor recommendations

2. The surface on which the PFP to be applied should be clean and free from grease, oil, rust etc.

3. Nuts are to be welded on the structural steel member with the spacing as approved by design/vendor requirement. The structure and nuts to be painted with compatible primer for PFP. Welding of nuts in vessel skirts and equipment's shall not be done without the instruction of engineer/inspector.

4. Expanded metal sheet shall be used at locations as per instructions of engineer/inspector.

5. Application of PFP shall be carried out by skilled and experienced persons.

6. All the items, equipment, structure, area etc to be protected with proper means to avoid the spillage of PFP material during the application.

7. For horizontal vessels, vessel skirts etc PFP to be applied in horizontal bands with working in the upward direction.

8. Thickness of the fireproofing to be established in consultation with engineer/inspector.

9. The Application of  the PFP shall be as per vendor instructions.
10. PFP shall be followed by two coats of micro-porous exterior top coat (or as per procedure) compatible with PFP.
11. All exposed areas between PFP and steel shall be sealed with proper sealant.

From the product catalogue of M/s.Carboline (Source:www.carboline.com)

Some Fire Proofing Material Manufactures are
1. www.carboline.com
2. PROMAT INDIA

References:

1. Materials Performance (October 2012) - Carboline supplement to MP

2. www.carboline.com

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