Structural Fireproofing PDF

Structural Fireproofing
By:
J. Gary Cizek, P.E., C.S.P
Baker Engineering and Risk Consultants, Inc.

•Types of Fire Protection

•What is Fireproofing
•General Fire Risks
•Fireproofing Application
•Fireproofing Inspection
•Fireproofing Maintenance
What types of Fire Protection options
are available?
¾Active Fire Protection
Water Sprays
Monitors
¾Passive Fire Protection

Fireproofing
Siting Strategies
Goals of Fireproofing
¾ Help maintain structural integrity of

supports and equipment exposed to
fires
Goals of Fireproofing
¾ Shield essential operating systems from

fire exposure
How Fireproofing works
¾ Limits flame spread and fuel load

with a high ignition temperature
¾ Increase the fire endurance of a

material thanks to low thermal
conductivity
To determine usefulness, risk

must be assessed
¾ High Fire-Potential
¾ Medium Fire Potential
¾ Low Fire-Potential
High Fire-Potential Risk
¾ Large spill of flammable liquid
¾ High temperature
¾ High pressure
High Fire-Potential Risk
Examples
¾ Fire Heaters
- Corrosive products
- Products that can create large spills
- Products that can clog piping
¾ Flammable liquid pumps rated over 200 gpm history
of failures or small piping
¾ High pressure reactors
¾ Compressors
¾ Vessels, HE containing flammables over 600 F
Ethylene Units, Catalytic Crackers, Hydrotreaters
Medium Fire-Potential Risk
¾ Small leaks of flammable liquids
¾ High temperature
¾ High pressure
Medium Fire-Potential Risk
¾ Examples
¾ Leaks from instrument or gaskets from
accumulators and feed drums
¾ Leaks from gauges and gaskets from towers
¾ Air-cooled fin-fans heat exchangers
¾ Highly automated peripheral equipment (air pre
heaters)
Low Fire-Potential Risks
¾ Any size release of combustible

liquids
¾ Negligible leaks of highly

flammable liquids
¾ Low Fire-Potential Risks
¾ Examples
¾ Pumps with class IIIB liquid below
flash point
¾ Piping within battery limits with high
concentration of valves, fitting and
flanges
¾ Flange leaks from heat exchangers
Fire Scenario
¾ Release mechanism
¾ Amount of fuel is released
¾ Severity of the fire
- Heat release
- Unabated burn time
Develop a fire scenario envelope
Determine appropriate protection rating
Fireproofing application
¾ Locations requiring Fireproofing
¾ Multilevel equipment structures and bracings
¾Locations requiring Fireproofing
¾Pipe racks and supports/aircoolers
¾Locations requiring Fireproofing
¾Tower, vessel supports
¾ Locations requiring Fireproofing
- Instrument, hydraulic and power cable trays
- Emergency valves
Fireproofing materials
¾Concrete Based
¾Dense Concrete
¾Advantages
- Can withstand thermal shocks and hose streams
- Can withstand flame impingement up to 2000°F
- Easy application
- Performance extensively proven (±4 hrs

protection)
¾Dense Concrete
¾Disadvantages
- High weight
- High Thermal conductivity
- Installation costly and time consuming

¾Lightweight Concrete
¾Advantages
- Lightweight material
- Better Fire protection properties than dense
Concrete
- Durable and low maintenance
- Can withstand flame impingement up to
2000°F
- Can withstand thermal shocks and hose
streams
- Easy to install
¾Lightweight Concrete
¾Disadvantages
- Porous material
- Moisture absorption leads to cracking and

spalling in freezing climates
- Need to maintain sealing coating
- Susceptible to mechanical damage

¾Subliming, Intumescent and Ablative Mastics
¾Subliming, Intumescent and Ablative
Mastics
¾Advantages
- A quick application
- Lightweight
- Suitable for use on existing supports that may
not handle additional weight
¾Subliming, Intumescent and Ablative Mastics
Disadvantages
- Application difficult due to the need to use proper mastic to
get satisfactory thickness and good bonding
- Experienced appliers are required
- Can be stripped away by fire firghting activities and flash
fires
- Can be less resistant to abrasion and mechanical impacts
¾Intumescent Epoxy Coating
¾Advantages
- Excellent bonding and corrosion protection
- Lightweight and durable under nonfire conditions
- Flexible and tolerates vibration
-Can have good durability in sever jet fire conditions

¾Intumescent Epoxy Coating
¾Disadvantages
- Char coating can be damaged during a fire
- Requires expertise in installation
- Concerns over possible toxic gases produced by charring

¾Spray Applied lightweight Cimentitious
Fireproofing
¾Advantages
- Lightweight
- Vermiculite allows for denting instead of cracking or shattering
¾Spray Applied lightweight Cimentitious
Fireproofing
¾Disadvantages
- Properties vary greatly with composition
- Not suitable for high vibration areas
- Great care must be taken to ensure proper application

thickness
¾Preformed Inorganic panels
¾ Preformed Inorganic panels
¾ Advantages
- Clean application
- No curing time
- Low thermal conductivity

¾ Fireproofing materials
Preformed Inorganic panels
¾ Disadvantages
- Labor intensive installation when instrumentation
and appurtenances are attached to columns
- Susceptible to impact damage

¾ Masonry blocks or bricks
¾ Advantages
- Easy Installation
- lightweight
¾ Masonry blocks or bricks
¾ Disadvantages
- High Installation costs
- High maintenance
- Admits moisture and cracks

¾ Endothermic Wrap
¾ Advantages
- Easy to repair and re-enter
- Material does not catalyze corrosion
- Can be applied directly over existing cement or
blocks where additional protection required
- Can be applied over other fireproofing
- Flexible wraps are explosion rated
¾ Endothermic Wrap
¾ Disadvantages
- Must be weatherproofed when used outdoors
- Weatherproofing must be done with manufacturers

specified protection tape to preserve recommended
protection
Fireproofing Inspection
¾ Survey coatings for
¾ Surface cracks delamination, rust stains, or
bulging
¾ Weathering
¾ Selectively remove samples to examine

conditions underneath, promptly repair
sample area
Fireproofing Inspection
¾ Coat spare pieces of steel during application

for further fire testing
¾ Inspect after maintenance to ensure

fireproofing has been replaced
Fireproofing maintenance
¾ Repairs needed when more than hairline cracking

appears
¾ Repairs needed when bulges, represent loss of

bonding, appear
¾ When Bonding failure is apparent

Remove fireproofing
Clean structure
Prime structure
Reinstall fireproofing
¾ Consult with manufacturer to

determine when surface coating
should be renewed.
Conclusion
¾ To ensure maximum life span and proper fire
rating:
- Ensure the right material is used
- Ensure installation is done correctly
- Inspection and maintenance is of utmost

importance

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Structural Fireproofing

Baker Engineering and Risk Consultants, Inc.

•Types of Fire Protection

¾Passive Fire Protection

¾ Help maintain structural integrity of

¾ Shield essential operating systems from

 How Fireproofing works

¾ Limits flame spread and fuel load

¾ Increase the fire endurance of a

 To determine usefulness, risk

 High Fire-Potential Risk

¾ Large spill of flammable liquid

 Medium Fire-Potential Risk

¾ Small leaks of flammable liquids

 Low Fire-Potential Risks

¾ Any size release of combustible

¾ Negligible leaks of highly

¾ Low Fire-Potential Risks

¾ Locations requiring Fireproofing

- Instrument, hydraulic and power cable trays

- Can withstand flame impingement up to 2000°F

- Performance extensively proven (±4 hrs

- High Thermal conductivity

- Installation costly and time consuming

- Moisture absorption leads to cracking and

- Need to maintain sealing coating

- Susceptible to mechanical damage

- Lightweight and durable under nonfire conditions

- Flexible and tolerates vibration

-Can have good durability in sever jet fire conditions

- Requires expertise in installation

- Concerns over possible toxic gases produced by charring

- Not suitable for high vibration areas

- Great care must be taken to ensure proper application

- Low thermal conductivity

- Susceptible to impact damage

- Admits moisture and cracks

- Weatherproofing must be done with manufacturers

¾ Selectively remove samples to examine

¾ Coat spare pieces of steel during application

¾ Inspect after maintenance to ensure

¾ Repairs needed when more than hairline cracking

¾ Repairs needed when bulges, represent loss of

¾ When Bonding failure is apparent

¾ Consult with manufacturer to

- Ensure the right material is used

- Ensure installation is done correctly

- Inspection and maintenance is of utmost

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How Fireproofing works

To determine usefulness, risk

High Fire-Potential Risk

Medium Fire-Potential Risk

Low Fire-Potential Risks