STANDARD

TECHNICAL SPECIFICATION

FIRE PROOFING OF STRUCTURES.

1.0 INTRODUCTION
     As a safety precaution the structural steel supports of various equipments
and structures are required to be encased in concrete (including providing
suitable nominal reinforcement steel rods / wire mesh) for the purpose of
fireproofing.
1.1 SCOPE OF WORK :
     Fire proofing of structural steel work by encasing in concrete or by
Guniting the surface.
  A Structural Steel : 
  a When supporting fire potential equipment within the battery limits,
columns and beams transmitting the equipment load to the columns shall
be fireproofed from their bases to a minimum height of 35 feet above
grade.
  b All bracing which contributes to the support of vertical loads or stability
of columns shall be fireproofed when part of a fireproofed supporting
system with the following additions or exceptions :
  i On structures over 30 feet in height, wind bracing shall be fire proofed.
  ii On structures less than 30 feet in height, bracing used only for wind
loading need not be fireproofed.
  c Platforms, runways, stairways and their supports need not be fireproofed.
  d Top flange of structural steel that supports floor plate need not be
fireproofed.
  B Equipment Support :
  a All lugs, brackets, skirts and legs supporting fire potential equipment
located within fire potential area and below a height of 300 feet from
grade (min.) shall be fireproofed.
  b Equipment supporting saddles measuring more than one foot in height at
their lowest points and located within fire potential area shall be fire
proofed.
  c Skirts :
  i Outside of all the skirts supporting process vessels shall be fireproofed. 
  ii Insides of skirts over 4 feet in diameter and bottom heads of
un-insulated
vessels supported on skirts over 4 feet in diameter shall be fireproofed.
  iii Skirts requiring insulation shall be fireproofed on their
un-insulated
portions only.
  iv Supporting legs of air cooled exchangers shall be fireproofed.
  C Heaters :
    Main supports and bracings (with exception of wind bracings) shall be
fireproofed
up to the  floor level of the heater.
1.2 SPECIFICATIONS :
    The specification of Cement, Coarse and fine aggregate, water and
reinforcement rods shall be as per 
Technical  Specifications of Tender.
1.3 CONCRETE STRENGTH :
    The specified characteristic Compressive cube strength of concrete at 28
days shall be 20 N / mm2 (min.)
1.4 PROTECTION :
    All concrete shall be adequately protected from mechanical or other
damage for 7 days from pouring. The concrete shall also be wet cured for
7 days from pouring starting from 24 hours of pouring by continual water
spray or wet cover.
1.5 GUNITING : 
  a Cleaning :
    Before applying Guniting to steel surface to be fireproofed, they shall be
mechanically cleaned to remove all scale, rust, loose concrete grease etc.
or any other material which will impair the bond between the surface of
the member to be encased and the gunite.
  b Proportion :
    Gunite shall be mixed in the proportion of one part of cement to approx. 3
parts of sand by loose volume. Actual proportion to be adjusted based on
quality of sand. The sand shall be screened over 6 mm screen.
  c Reinforcement :
    The reinforcement shall consist of 2" x 2" galvanized fabric 12 gauge bent
to a template confirming to the outline of the member and secured in
place with minimum 18 gauge binding wire with the nuts welded to
structure.
  d Pressure :
    The cement gun shall be operated at a pressure of 30 lb / sq. inch gauge
on the gun tank
up to 100 ft. of hose. The pressure shall be increased
thereafter by 5 lb / sq. inch for every additional 50 ft. or part thereof of
hose.
  e Application of Gunite :
    The water use for mixing shall be free from oil, salt, acid, alkali, vegetable
matter etc. The consistency of the mix shall be controlled by the nozzle
operator. Too much water washers away material and too little water
results in unsound gunite. It is therefore essential to use highly
experienced operator.
The nozzle shall always be held at right angles to
the surface to be gunited and at a distance of approx. 75 to 90 cms.
On
vertical surfaces the limit of the thickness that can be built is reached
when material starts to sag or separate.
On horizontal surfaces the depth
is a factor of the plasticity and the limit is reached when material starts to
spatter or show other evidence of moisture.
The thickness of Guniting
shall be minimum 50 mm. The thickness may be built if necessary in
layers. Longer the interval between the applications (while the first
material is still plastic) greater the thickness which can be applied
without separation. Each preceding layer shall be light broomed prior to
time of Initial Set and cleaned with a stream of water or blast of air and
water prior to application of succeeding layer.
Curing shall be done with a
light spray of water as soon as possible without damaging final finish.
Final finish may be obtained by brushing with a brush after application of
finish layer of gunite.
Shooting at surface should start at bottom and
should be worked up for vertical surfaces. For dish end the shooting shall
start at circumference and shall be completed at the
center.
  f Precautions
  i Gunite shall not be applied when air temperature is less than 5 deg. C.
  ii At the end of day's work, slope off the gunite to thin edge. Before
resuming clean the surface and wet with water. Cut out loose pockets of
sand and replace with gunite.
  iii Apply gunite preferable after all piping work is completely assembled.
1.6 SPECIAL INSTRUCTIONS :
  1.6.1 Tack welding of reinforcement rods, cleats, nuts etc. wherever required
shall be covered in unit rates for fireproofing. 
  1.6.2 Where steel rods and encasing is provided on only 3 sides of a Beam, the
rods shall be welded to beam.
  1.6.3 The rates of concreting shall include cost of providing and removing from
work and cost of fabricating reinforcement steel rods.
1.7 Alternative to the system of encasing /
Guniting Cement concrete (M20)
described in specification above, encasing with light weight cementatious
material of the following specification or equivalent duly approved by the
client / engineer shall be supplied by the contractor. Contractor's scope of
work will be inclusive of all labour, materials, tools and tackles,
equipments and any other services required for successful completion of
the alternative system of encasing.
    SPECIFICATION FOR FIRE ENCASING WITH LIGHT WEIGHT CONCRETE :
  a Encasing Material shall have following composition :
  i OPC (Ordinary Portland Cement) conforming to IS : 8112.
  ii Light weight
(vermiculite) aggregate.
  iii Suitable insulating binders and additives.
      Proportioning by weight of the above materials, (equivalent volumes)
should give following properties as in (b) to (d)).
  b Density : 800 to 900
Kg/M3.(Max.)
  c Compressive Strength : 20 to 25 Kg/cm2 (Min.)
  d Thermal Conductivity : 0.174 Kcal/hrm2 / deg. C
  e Anchorage for
tying the reinforcement :
     It shall consist of 3/4" STD or hexagonal nuts or 16 g GI wire.
  f Reinforcement :
    It shall be done with welded wire mesh of 14 g with 2" x 2" mesh tied to
the anchor nuts / lugs.
  g Painting :
    The encased concrete surface shall be painted with 2 coats of cement
based paint of approved make and quality after proper curing.
  h Sealing :
    Top exposed joint between the encasing material and steel surfaces shall
be sealed with 
cement mortar (1:1). 
    METHOD OF APPLICATION :
  1 All steel surfaces before application of fireproofing shall be oil loose rust
or mill scale by wire brushing and oil/grease deposits shall be removed
with detergents.
  2 Attach the reinforcing Wrapper firmly in place of structural steel members
or vessel skirts. The wrappers shall be tied to the nuts so that it is held
3/4 to 1 inch from the face of support.
  3 For placing the concrete in position pneumatic application shall be done in
most cases except for small areas and in accessible locations.
  a The nozzle shall be held perpendicular to the surface except where
reinforcement is encountered in which case the concrete should be shot
around the reinforcement.
  b The water content shall be adjusted so that the concrete adheres properly
and does not sag and slide upon application.
  c For vessel skirts and columns the concrete shall be applied in horizontal
 bands working upwards from the bottom of the skirts. The full specified
thickness shall be developed in three successive layers. It is important
that each successive layer is bounded to the developed its initial stage.
Therefore the application will be governed by the area and atmospheric
conditions. In case of structural columns, beams and bracing necessary
formwork shall be done before applications.
  d Once the application has started it shall proceed continuously. If the
application is interrupted and does not satisfy successive layers criteria
the concrete shall be cut back to the substrate with trowel at an inclined
angle. Immediately prior to resuming application the exposed surface of
the concrete to which a bond must be made shall be thoroughly wetted.
  e Areas adjacent to pneumatic application should be shielded to prevent
splatters and excessive clean up. The cleaning shall be done prior to
initial set.
  f The desired finish shall be
trowelled to flat finish immediately after
Guniting is complete.
  g Immediately during initial set-up while the concrete is still moist, all the
necessary pointing shall be done.
  h The concrete shall be cured by keeping it in damp condition for a period of
7 days else the surface shall be given a sprayed on coat of curing
compound.
  4 Fireproofing shall be coated with 2 coats of cement based paint of
approved make and shade after complete curing.
  5 Sealing of top exposed joints between concrete and steel on surfaces
shall be done with
neat cement mortar (1:1) to fill up all crevices left
during Guniting.