Objectives

• How passive fire protection (PFP) works

• Testing and certification requirements for epoxy PFP
• Main factors that determine PFP thickness
• Advantages of Pyroclad X1
• Estimating a project
• Sample specification
• Application methods and equipment
How Passive Fire Protection
(PFP) Works
 Why Protect Steel?

• To protect assets
• Maintain points of egress
for personnel
• Prevent structural
collapse
• Save lives
Why Does Steel Require PFP?
• Steel looses load carrying
capacity as the core temperature
increases
• Steel begins to deform at 427 °C
(800 °F)
• PFP extends the time it takes to
reach the failure point
• Limiting temperature is project
specific
(200°C - 600°C / 392°F - 1112°F)
• Most projects require 400°C
limiting temperature
 Pyroclad X1 Description
• 100% solids (solvent free)
• 2 component epoxy PFP
• Jet fire and hydrocarbon pool fire
protection for structural elements, beams,
columns, bulkheads, underdecks and
risers.
• Light weight / Low density: 1.03 g/cm³
• High Temp Mesh (carbon fiber)
 How Pyroclad X1 Works
• Applied like a paint in multiple
passes (5 mm/coat)
• Durable finish that can be
topcoated
• Passive coating under normal
conditions
• When exposed to fire,
Pyroclad X1 intumesces, or
“swells” up to 10 times original
thickness producing a heat
blocking “char”
• Reaction insulates steel for a
given amount of time
Testing And Certification
 Fire Environments

• Sonic velocity, high pressure torching

• Simulates burning pressurized burning gas
Jet Fire • Erosive fire environment
• ISO 22899 (onshore / offshore)

• Non-torching hydrocarbon fire

Hydrocarbon • Simulates burning pool of hydrocarbon fuel
Pool Fire • UL 1709 (onshore)
• ISO 834 / BS-476 (offshore)
 2400
Fire Testing Curves 1315

2200 1204

2000 1093

1800 982
1600 871
1400 760

Temp ( C )
Temp ( F )

1200
649
1000
538
800
427
600
316
400
204
200
93
0
0 20 40 60 80 100 120 140 160 180 200 220 240

Jet Fire (ISO 22899-1) Time (minutes)

Hydrocarbon Fire (UL 1709)
Hydrocarbon Pool Fire (BS-476/ISO 834)
 Testing Requirements
• Hydrocarbon fire testing (simulates pool of burning hydrocarbon fuel)
-IS0 834 / BS 476 Part 20-21 Appendix D (offshore)
-UL 1709 (onshore)
• Jet fire testing (simulates pressurized burning gas)
- IS0 22899-1
• Environmental testing (simulates atmospheric exposures)
- NORSOK M-501 System 5A (offshore)
- UL 1709 Environmental test program (onshore)
• Performance testing (explosion resistance and hose stream resistance)
- Overblast explosion testing
- NFPA 58 Annex H hose stream testing
• Physical property testing
- Compressive, flexural, tensile, impact, hardness, thermal conductivity,
adhesion/cohesion, flame spread/smoke development, moisture absorption
Hydrocarbon Fire Testing
(ISO 834/BS-476)

Tested For:
- I-Sections
- Tubular Sections
- Divisions(Bulkheads/Decks)
Jet Fire Testing (ISO 22899)

Tested For:
- I-Sections
- Tubular Sections
- Divisions(Bulkheads/Decks)
 NORSOK M-501 Rev 6 Testing
• Exposed to 25 cycles accelerated aging (ISO 20340)
• Corrosion/bond strength panels / Fire test panels
• Each 168 h (1 week) cycle includes:
3 Days 3 Days 1 Day

U VA 340 Bulb ISO 7253 Salt Fog

5% NaCl at 35° C

4 hrs. UV at 60° C / 4 hrs. Condensing at 50° C Thermal Shock at

-20° C

• 72 h of UV/condensing moisture (ISO 11507)

• 72 h of salt spray (ISO 7253)
• 24 h thermal shock at -20°C
NORSOK M-501 Rev 6 Testing
Pass/Fail Criteria:
• Corrosion creep < 3mm
• Adhesion > 3 Mpa
• Fire performance within
10% of non aged sample
 NORSOK M-501 Rev 6
Fire Testing
• Fire tested in both vertical and
overhead configurations
• Aged samples performed within
10% of non-aged samples in
side by side test
Passes NORSOK M-501 Rev 6
Without Topcoat
• Full pass without a
topcoat
(only 0.2% moisture
uptake)
• Minimal corrosion creep:
< 3 mm
• Maintains adhesion:
> 3 Mpa
• No significant loss of fire
properties in aged
samples
 Overblast Testing
• Simulates explosion
• Successful overblast
bulkhead testing
• 5” (127 mm) deflection over
6’ (1.8 m) span
• No cracking or delamination
• Ensures material performance
 Hose Stream Testing
• Simulates high pressure
water stream of fire hose
• NFPA 58, Annex H Hose
Stream Test
• Retains integrity during
fire
while exposed to hose
stream
• Maintains fire
performance
 Physical Properties
Property Pyroclad X1 Leading Competitor
Water Absorption 3.3% (untopcoated)
(Total immersion in 5% salt solution @ 0.5% (untopcoated)
room temperature for 76 days)
1.4% (topcoated)
Water Absorption 0.2% (untopcoated) Not published
NORSOK M-501 System 5A (4,200 hours)

Hardness Shore D 70 Shore D 70

ASTM D2240

Compressive Strength 3,672 psi (25.3 MPa) 2,700 psi (18.6 MPa)
ASTM D695

Flexural Strength 3,925 psi (27.1 MPa) 3,300 psi (22.7 MPa)
ASTM D638

Adhesion/Cohesion 1,840 psi (12.7 MPa) 1,450 psi (10.0 MPa)

ASTM D4541 (average) (average)
Flame Spread 20 25
ASTM E84

Smoke Development 65 130

ASTM E84
 Certification Authorities
• Choice of certification
organization is dependant
on project requirements
• Lloyd’s Register (LR)
• Det Norske Veritas (DNV)
• American Bureau of
Shipping (ABS)
• Underwriter’s
Laboratories, Inc. (UL)
• NORSOK
(Environmental)
Pyroclad X1 Certification Types
• Structural steel (LR, DNV, ABS)
- I-sections (beams and columns)
• Tubular hollow sections (LR, DNV, ABS)
- Rectangular hollow sections
- Round hollow sections
• Divisions (LR, DNV, ABS)
- Bulkheads
- Decks
- Firewalls, blast walls, accommodation modules
- H Class (H-0, H-60, H-120)
- J Class (J15, J-30, J-60, J-120)
*Ratings will vary with member type.
 Service Environments
• Offshore
- Offshore platforms
- Oil and gas installations
- FPSOs

• Onshore
- Refineries
- Petrochemical plants
- LNG terminals
- LPG storage facilities
Structural Steel I-Sections
Tubular Hollow Sections
Structural Steel I-Sections/Tubes
Tank Supports
Vessel Skirts
Fire Rated Divisions
(Underdeck)
Fire Rated Divisions
(Bulkhead)
 Fire Rated Divisions
(Accommodation Modules)
 Fire rated Divisions
• Hydrocarbon Fire
- H Class
- H-0, H-60, H-120
• Jet Fire
- J Class
- J15, J-30, J-60, J-120
• Prevent heat transfer and
passage of flame and smoke
from the fire exposed side to the
non-exposed side during a 2 hour
hydrocarbon fire test
 H Class Divisions
• Non-exposed side must stay below 140°C (average) / 180°C (single
point) above ambient for designated time
• No flame or smoke penetration for 2 hours
• H-0 only must only stay below 400°C for 2 hours (no flame and
smoke requirement)

Fire Class Time (minutes)

H-0 0

H-60 60

H-120 120
 J Class Divisions
• Non-exposed side must stay below 140°C (average) / 180°C (single
point) above ambient for designated time
• No flame or smoke penetration for 2 hours
• To calculate the thickness required, the jet fire erosion factor is
added to the required hydrocarbon thickness (from appropriate
certification)
Fire Class Time (minutes)

J-15 15

J-30 30

J-60 60

J-120 120
 How To Determine Thickness
Requirement
• What type of structural member (I-section, hollow section,
division)?
• What is the Hp/A section factor (30-300)?
• What is the critical “limiting temperature” for the project
specification?
• What is the fire duration?
• What is the fire type (hydrocarbon, jet or combination)?
• What classification has to be used (LR, DNV, ABS, UL)?
• If plate or division, what is the thickness of the steel?
• If division, what fire class and duration is specified
(H or J / 0, 15, 30, 60, 120 minutes)?
 Factors That Affect PFP
Thickness
• Hp/A: Heated perimeter/Area
• Steel with smaller Hp/A has
greater mass
• The more mass a steel section
has, the less PFP thickness it
requires
• The higher the critical limiting
temperature, the less thickness
is required
• The longer the fire durations
require more thickness
• Jet fire ratings require jet fire
erosion factor to be added to
hydrocarbon thickness
Critical Limiting Temperature
• Temperature at which strength of steel will fall
below limit required for the project.
• Specified by project, may vary for structural
supports, equipment, piping, etc.
• 200oC-600oC (392oF-1,112oF) for jet fire and
hydrocarbon protection
• 400oC (752oF) typical
• Specification may vary according to project and
operational requirements
Hydrocarbon Ratings
Example
 Jet Fire Erosion Factor
• Additional material added to hydrocarbon
thickness to withstand the effects of the jet
fire.
• Thickness differential between hydrocarbon
and jet fire is “jet fire erosion factor”.
• Compares thickness requirements for specific
steel size (Hp/A: 100) at same limiting
temperature (hydrocarbon fire vs jet fire)
• The jet fire erosion factor is added to the
hydrocarbon thickness required.
Pyroclad X1 Coating Systems
Primers Topcoats
Carboguard 888 Carbomastic 94 (6 mils/150 microns)
Carboguard 890 Carbothane 134 HG (2-3 mils/50-75 microns)
Carboguard 893 SG
Carboguard 60
Carboguard 635
Carbomastic 94
Carbomastic 615
Carbozinc 858 Global
Carbozinc 11 HS / Carboguard 893

All other primers and topcoats must be approved

Primer or primer system thickness shall be between 3-5 mils (75-125 microns)
Primers and topcoats in bold are part of NORSOK tested system
 Mesh Reinforcement
• High Temp Mesh used for all applications
• Approximately 1,000 ft² (93 m²) roll
• Installed at nominal midpoint to 2/3 point.
• Mesh placement and overlap requirements
will depend on the configuration of the
steel and the fire exposure type.
Mesh Reinforcement
Mesh Reinforcement
Performance Advantages of
Pyroclad X1
 Advantages of Pyroclad X1
Pyroclad X1 Competitor A Competitor B Competitor C
Best
Mix Ratio 2.45:1 2.33:1 2.36:1
1:1
Overall Thickness
Lowest Low Highest Higher
Requirements

Installed Weight Lowest Low Highest Higher

Best (0.2%) 3.3%

Water Absorption Worst >4% Not published
Un-topcoated Un-topcoated

Shore D Hardness Best (70) Best (70) Lowest (25) Lower (60)

Best Best
Weathering
Passed without Passed without Topcoat required Topcoat required
(NORSOK Test)
topcoat topcoat

Compressive Strength Highest High Lowest Lower

Flexural Strength Highest High Lowest Lower

Performance Advantages of Pyroclad X1
1. “Pyroclad X1 has lower overall thickness requirements for structural steel.”
- Industry leading hydrocarbon ratings / competitive jet fire erosion factors
- Tremendous weight savings to overall structure
- Requires less material and labor to install / lower installed cost
2. “Pyroclad X1 has the lowest moisture absorption of any PFP material on the
market.”
- Successfully passed NORSOK M-501 System 5A without a topcoat
- High resistance to moisture uptake during and after application (0.2%)
- Provides assurance that material will stand up to harsh offshore environments
- Lower maintenance and repair costs
3. “Pyroclad X1 has highest durability.”
- Highest Bond Strength, compressive strength and flexural strength
- Provides better resistance to damage during construction and while in service
- Better adhesion, longer service life
- Lower maintenance and repair costs
Application Advantages of Pyroclad X1
1. “Pyroclad X1 has lower overall thickness requirements for structural steel.”
- Less coats to apply
- Faster application
- Less material and labor required to achieve rating
2. “Pyroclad X1 has a simplified 1:1 mix ratio.”
- Minimizes off ratio application
- Easy visual verification
- Simple straight forward application
3. “Pyroclad X1 is easiest to apply.”
- Best spraying material on the market
- No special procedures needed to obtain correct spray applied density
- Excellent fan pattern and thickness control
- Fast recoat intervals
Thickness Comparison
Estimating A Project
 Density And Coverage
• Pyroclad X1 is sold in 40 kg and 20 kg kits
• Wet density in can is 1.30 g/cm³
• Actual coverage better than theoretical due to
entrained air (20-27% better coverage)
• Typical spray film density ranges between 1.03-
1.10 g/cm³ depending on application parameters
• A spray applied density of 1.03 g/cm³ is
achievable by following Carboline guidelines
 Project Estimation
Steps:
1. Find thickness required for specified rating using Hp/A charts
2. Multiply thickness (mm) x density (g/cm³)
= weight per unit area in (kg/m²) @ specified thickness
3. Multiply weight per unit area x total m² of project
= total material needed for project in kg
4. Divide by kit weight (40 kg or 20 kg kit)
= number of kits for project
5. Multiply weight per unit area x price per kg
= material cost per m²
 Packaging
• Supplied in 40 kg (full) and 20 kg (half) kits
• Full kits for plural application
• Half kits used for single component and
trowel applications
Typical Pyroclad X1 Specification
• Prepare steel to Sa 2-1/2 (SSPC-SP10) with
37.5 - 50 micron profile
• Apply approved primer @ 75-125 microns (3-5
mils) DFT
• Apply Pyroclad X1 to point of mesh placement
• Apply High Temp Mesh in proper orientation
• Apply Pyroclad X1 to specified thickness
• Apply approved topcoat to specified thickness
 Typical Fire Ratings
1. Hydrocarbon Pool Fire (Offshore)
- IS0 834 / BS 476 Part 20-21 Appendix D
- 30 minute – 180 minute
2. Hydrocarbon Jet Fire (Onshore/Offshore)
- ISO 22899-1
- 15 minute – 120 minute
3. Hydrocarbon Jet Fire and Hydrocarbon Pool Fire
Combination
- Any combo of time intervals
4. Hydrocarbon Fire (Onshore)
- UL 1709
- 1 hour – 4 hour
 Example Fire Rating
Specification: J30 / H90 for structural
steel
30 minute jet fire
+90 minute hydrocarbon
120 minute total
400°C limiting temperature
Structural I-section (Hp/A: 60)
Jet / Hydrocarbon Fire Example
STEP 1: Generate required thickness:
1. Add 30 + 90 = 120 minutes total
2. Go to the 400°C chart for Hp/A: 60 @ 120
minutes to get hydrocarbon rating = 6.9 mm
3. Look up jet fire erosion factor for 30 minute
for member type = 1.8 mm jet fire erosion
factor
4. Add 6.9 mm + 1.8 mm = 8.7 mm (required
thickness)
 Project Estimation
STEP 2: Calculate Pyroclad X1 quantity
• Project size: 10,000 m²
• Pyroclad X1 thickness: 8.7 mm
• Pyroclad X1 density 1.03 g/cm³
• 8.7 mm (thickness) x 1.03 g/cm³ (density) = 8.96
kg/m² @ 8.7 mm
• 10,000 m² x 8.96 kg/m² = 89,600 kg of Pyroclad X1
• Estimated loss and overspray: 20%
89,600 kg /.80 = 112,000 kg
• 112,000 kg / 40 kg (full kit) = 2,800 kits required
 Coatbacks
• Extension of PFP beyond primary
member onto the secondary non-
fireproofed member
• Prevents heat transfer to primary
member
• Secondary members protection is
at the discretion of project
• The coatback requirement is
project specific, a typical coatback
requirement is 18” (450 mm) from
the primary member.
• Ensure this is included in project
planning
Application
Application Methods
• Plural component
• Batch mix
• Trowel
Approved Equipment Suppliers

Spray Quip
WIWA
Plural Component Spray
Equipment
Single Component Spray
Equipment
Trowel Application tools
Acceptable Finish
Questions?