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Sheet 1 of 11

ENGINEERING SPECIFICATION

FIRE PROOFING OF STEEL STRUCTURES

FOR

CIVIL WORKS

FOR

HINDUSTAN PETROLEUM CORPORATION LTD.

VISAKH REFINERY

DHT PROJECT
TEIL JOB NO. : 6261
DOCUMENT NO. : A-320

A 01.06.09 For Bid Enquiry UCM PRK SSV

Rev.
Issue Date Description Prepared by Checked by Approved by
no.

TOYO ENGINEERING INDIA LIMITED

MUMBAI INDIA
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Sheet 2 of 11

Revision History

Rev. Date Description

A 01.06.09 For Bid Enquiry
 < Security Level 2 >

FIRE PROOFING OF STEEL

STRUCTURE
HPCL, Visakh TOYO ENGINEERING INDIA LTD.
ISSUED : 29.12.2008 JOB NO. : 6261
DOC.No: A-320 DHT PROJECT Sheet 3 of 11

CONTENTS

SR. NO. DESCRIPTION PAGE NO.

1.0 SCOPE 4

2.0 APPLICABLE CODES 4

3.0 PRIORITY OF REQUIREMENTS 4

4.0 GENERAL 4

4.1 Purpose 4

4.2 Fire Resistance Rating 4

5.0 CRITERIA OF FIRE PROOFING 5

5.1 Pipe Racks 5

5.2 Equipment Supporting Structures 5

6.0 SURFACE PREPARATION 5

7.0 FIRE PROOFING BY GUNITING 5

8.0 FIRE PROOFING BY IN-SITU CONCRETE 6

(ENCASING)

9.0 VERMICULITE CEMENTITIOUS COATING 6

10.0 APPLICATION 7

11.0 SKETCHES FOR FIRE-PROOFING DETAILS 8

SKETCH-1 CONCRETE FIRE-PROOFING TO BEAMS & 9

BRACINGS

SKETCH-2 CONCRETE FIRE-PROOFING TO COLUMNS 10

SKETCH-3 MISCELLENEOUS DETAILS 11

 < Security Level 2 >

FIRE PROOFING OF STEEL

STRUCTURE
HPCL, Visakh TOYO ENGINEERING INDIA LTD.
ISSUED : 29.12.2008 JOB NO. : 6261
DOC.No: A-320 DHT PROJECT Sheet 4 of 11

1.0 SCOPE

This specification covers materials and methods of application for fireproofing of

steel structures and equipment supports.

2.0 APPLICABLE CODES

Note: - Wherever reference is made to IS Codes, on any page of this Technical

Specification (including annexures), applicable year of publication of IS
Code is as stated below.

The Indian Standard Codes applicable to this section shall include but not
limited to the following:

IS 1566 - 1982 : Hard drawn steel wire fabric for concrete

reinforcement.

IS 6433 - 1972 : Specification for guniting equipment.

IS 9012 - 1978 : Recommended practice for shotcreting.

3.0 PRIORITY OF REQUIREMENT

In case of any variation and discrepancy in condition between the special

conditions, this specification and codes, order of priority shall be as under:-

(1) Special conditions

(2) This specification

(3) Codes

4.0 GENERAL

4.1 Purpose

Fire proofing is aimed at providing resistance to all the load bearing steel
structures and equipment supports that would collapse under fire conditions and
contribute to the intensity of the fire.

This fire resistance would allow the people to be evacuated and fire to be
suppressed.

Therefore, the supports of all potential fire sources shall be fireproofed.

The support of non-potential fire hazards shall also be fireproofed, if their

collapse is likely to endanger other hazardous equipments.
 < Security Level 2 >

FIRE PROOFING OF STEEL

STRUCTURE
HPCL, Visakh TOYO ENGINEERING INDIA LTD.
ISSUED : 29.12.2008 JOB NO. : 6261
DOC.No: A-320 DHT PROJECT Sheet 5 of 11

4.2 Fire Resistance Rating

A minimum of 2 hours fire resistance , shall be applied, unless specified

otherwise.

5.0 CRITERIA OF FIRE PROOFING

5.1 Pipe Racks

5.1.1 Pipe rack main members such as columns, girder, beams and vertical bracings
withstanding long term loads shall be fireproofed upto the first pipe support level,
in the fire hazardous area, unless specified otherwise.
5.1.2 Where equipments such as Air Fin coolers are supported on the pipe rack, fire
proofing for columns shall be extended upto the equipment support level and the
structural members transmitting the equipment loads shall be fire proofed.

5.1.3 The top flanges of beams supporting the pipes shall not be fire proofed.

5.1.4 Pipe racks outside the fire hazardous area shall not be fire proofed.

5.2 Equipment Supporting Structures

5.2.1 Where structure supports the equipments classified to the potential fire hazard,
columns shall be fire proofed from the base plates to the equipment support
level.

The beams and bracings transmitting the equipment loads to the columns shall
be fire proofed.
5.2.2 Platforms, stairways and their supports shall not be fireproofed.

6.0 SURFACE PREPARATION

6.1 Steel surfaces to be fire proofed, shall not be painted and shall be cleared of all
loose dirt, rust, mill scale, soot and concrete by mechanical wire brushing or shot
blasting. Oil and grease deposits shall be removed with detergents and steel
surface made clean and dry.

6.2 Pipes and equipment in the vicinity shall be covered by tarpaulins to prevent
them from spatter. Rebound and spatter which may enter open ends of pipe
lines in the vicinity shall be protected by wood plugs or other suitable shields.

7.0 FIREPROOFING BY GUNITING

7.1 Materials, equipment and method of application shall be in accordance with IS

9012 and IS 6433. Placement shall be done only by skilled operators as
approved by Engineer-In-Charge
 < Security Level 2 >

FIRE PROOFING OF STEEL

STRUCTURE
HPCL, Visakh TOYO ENGINEERING INDIA LTD.
ISSUED : 29.12.2008 JOB NO. : 6261
DOC.No: A-320 DHT PROJECT Sheet 6 of 11

7.2 Hard drawn steel wire fabric of 2.5mm dia, 50 x 50mm mesh conforming to IS
1566 shall be used as reinforcement. The fabric shall be secured by 18 SWG
galvanized tie wire to studs or spacers. Spacers shall be 5mm thick. Steel wire
fabric reinforcement shall be placed, to maintain a clearance of not less than
20mm from the face of the member. Adjacent sheets shall be lapped at least
75mm and securely tied together.

7.3 Shooting strips shall be used to obtain proper thickness and true lines over
flanges, angles and re-entrant corners. Strips shall be designed to permit
escape of rebound.

7.4 The finish shall be wooden float or sponge trowelled sufficient to obtain a
uniform appearance without attracting excessive laitance to the surface.

7.5 Immediately after final finishing, surfaces shall be given a one spray coat of an
approved curing compound.

Brand name, name of manufacturer and test results shall be submitted to and
got approved from the Engineer-In-Charge prior to procurement and use of
curing compound.

7.6 Shotcrete thus applied shall develop not less than 24 N/mm² compressive
strength in
28 days.

7.7 All outside edges of fire proofing shall be chamfered / rounded off by 20mm.

7.8 The fixing of the reinforcing fabric shall be robust and in sufficient quantity to
secure the fabric in the required position at all stages of the fire proofing
application.

7.9 The junction between fireproofing and bare steel shall be sealed against ingress
of water, with minimum 10 mm thick mastic flashing. When not otherwise
shielded.

7.10 Bags of cement shall be kept dry until ready for use, stored off the ground, under
cover and away from wet or damp surfaces or areas of high humidity.

7.11 The mixing shall be made in concrete paddle blade mixers in accordance with
the manufacturer’s instructions. The water added shall be of potable quality.

7.12 Unless specified otherwise, the thickness tolerance shall be –2/+3mm. Each
face shall be checked for thickness every 4m and at least once per member.

8.0 FIRE PROOFING BY IN-SITU CONCRETE (ENCASING)

8.1 Concrete for fire proofing shall be M20 grade. Mixing and placing shall be done
as per TEIL specification no. A-318.

8.2 Minimum thickness of concrete coating over the steel shall be 50 mm.
 < Security Level 2 >

FIRE PROOFING OF STEEL

STRUCTURE
HPCL, Visakh TOYO ENGINEERING INDIA LTD.
ISSUED : 29.12.2008 JOB NO. : 6261
DOC.No: A-320 DHT PROJECT Sheet 7 of 11

8.3 Concrete shall be poured into forms properly oiled and made to correct
dimensions. Concrete shall be vibrated as necessary to ensure smooth surface,
free from voids and irregularities. Any defects, honey comb etc. shall be rectified
by LSTK contractor at his own cost.

9.0 VERMICULITE CEMENTITIOUS COATING

9.1 Design Specifications :

9.1.1 Vermiculite cementitious coating shall restrict the temperature of a vessel /

structure below 427o C for vessel supports & skirts and 550o C for structural
steel members, for a minimum time of 2 hours. The material shall not fail till the
end of specified time period.

9.1.2 The coating shall be strong enough to withstand thermal shock and
impingement of water from fire hoses and / or monitors.

9.1.3 The coating shall be asbestos free and shall be non corrosive to steel members
and shall not be affected by environmental conditions, or from local leakages,
spillage or pollution.

9.1.4 The coating material shall be easily repairable and shall be durable.

9.1.5 Application procedure of the coating shall be non hazardous, shall not interfere
with the working of adjoining areas and shall be easy.

9.1.6 The LSTK contractor shall submit calculation for the thickness of coating for all
structures to be fireproofed for approval from the Engineer-In-Charge for the
particular branded product he is going to use, but in no case the coating shall be
less than 40 mm.

10. APPLICATION

Vermiculite cementitious coating shall be mixed with water in a suitable mixer or on

clean platform as per manufacturer’s specifications. Water cement ratio shall be
adjusted so that vermiculite cementitious coating adheres properly to steel surface and
does not sag or slide after applying.

Application of primer suitable with vermiculite cement coating as specified by

manufacturer shall be applied over the steel surface after cleaning the shop primer, it
required as per the manufacturer’s specifications.

Generally spray gun shall be used for the application of the mixed vermiculite
cementitious coating, except for small or inaccessible locations, where application with
hand tools shall be permitted. Mixed vermiculite shall be used within the pot life
specified by manufacturer. Under no circumstances rebound material shall be used.
 < Security Level 2 >

FIRE PROOFING OF STEEL

STRUCTURE
HPCL, Visakh TOYO ENGINEERING INDIA LTD.
ISSUED : 29.12.2008 JOB NO. : 6261
DOC.No: A-320 DHT PROJECT Sheet 8 of 11

The full specified thickness shall be developed in three successive coats.

Initial Coat : Thickness between 8 mm to 12 mm.

Intermediate Coat : Thickness between 18 mm to 22 mm to give total

thickness of 30 mm upto Intermediate coat.

Final Coat : Not less than 8 mm thick.

Each successive layer shall only be applied after the previous layer has
developed its initial set and is also properly scratched with steel brush to
roughen the surface to develop proper bond. If the application is interrupted and
does not satisfy successive layers criteria, the coating shall be cut back to the
steel surface proceeding layer with a trowel at an inclined angle. Exposed
surface of this coating shall be thoroughly wetted before resuming the work.
o
Application of mixed vermiculite shall not be carried out if the air temperature is 4 C
or less. Provision shall be made for adequate ventilation during and after application,
until the coating is dry.

2 coats of micro-porous exterior top coat, compatible to cement surfaces, of

approved make & colour conforming to IS specifications, should be applied, over the
fire proof coating.

Sealing with minimum 10 mm thick bitumen mastic flashing, shall be carried out at
all exposed joints between fire proofing material coating & steel.

11. SKETCHES SHOWING FIRE-ROOFING DETAILS

Fire –proofing work shall be carried out as per the sketches shown below.
 < Security Level 2 >

FIRE PROOFING OF STEEL

STRUCTURE
HPCL, Visakh TOYO ENGINEERING INDIA LTD.
ISSUED : 29.12.2008 JOB NO. : 6261
DOC.No: A-320 DHT PROJECT Sheet 9 of 11

SKETCH-1
 < Security Level 2 >

FIRE PROOFING OF STEEL

STRUCTURE
HPCL, Visakh TOYO ENGINEERING INDIA LTD.
ISSUED : 29.12.2008 JOB NO. : 6261
DOC.No: A-320 DHT PROJECT Sheet 10 of 11

SKETCH-2
 < Security Level 2 >

FIRE PROOFING OF STEEL

STRUCTURE
HPCL, Visakh TOYO ENGINEERING INDIA LTD.
ISSUED : 29.12.2008 JOB NO. : 6261
DOC.No: A-320 DHT PROJECT Sheet 11 of 11

SKETCH-3 MISCELLENEOUS DETAILS