P22-1TS-6455 TECHNICAL STANDARD FIREPROOFING OF STRUCTURAL ELEMENTS (INCLUDING STEEL VESSEL SUPPORTS) eo] CERRO NEGRO PROJECT Nv JOSE UPGRADER Jose, Venezuela 2 b0% 47) fee? Fez Bip BoseCerro Negro FIREPROOFING OF STRUCTURAL TECHNICAL STANDARD Project ELEMENTS (INCLUDING STEEL VESSEL : i ponte P22-47S-6455 Jose Upgrader REVNo. 0 | SEP 1897 Page 1 of & ‘TABLE OF CONTENTS Section tle Page No. GENERAL ‘ 1 Scope .... 2 Definitions REFERENCES: 1 2 American 3 American 4 5 QUALITY. 7.4 Quality Cor 72 Submittals 73 inspection 8 INSTALLATION OF FIREPROOFING is 81 General 82 Concrete 83 Proprietary Fireproofing Figure 4 Figure 2 Figure 3 Figure 4 1. GENERAL 4.1 Scope Project Specifications Underwriter's Laboratories (UL) ...... Concrete Reinforcing Ste! institute (CRS) FIREPROOFING ZONES .... EXTENT OF FIREPROOFING .... ae MATERIALS eee ANCHORAGE Concrete Institute (ACI) 11! Society for Testing and Materials (ASTM) ASSURANCE ntrol . and Testing Typical Concrete Fireproofing . Top of Column Fireproofing Metal Lath Stud on Skit. Fireproofing of Vessel Skirts, ©O0® VIOOUASRRONNNNNNND Oooo This standard covers the application of fireproofing materials to structural steel and the supporting element 4.2 Definitions “Company” Joi “Engineer* The Company or the Engineering, Procurement and ts of equipment. int Venture (JV) Construction Contractor (EPC) responsible fo the Company “supplier” The organization responsible for performing the work identified in the Order “Order” ‘The package of documents defined in the contract, 2, REFERENCES ‘The following publications and codes form a part of this Specification. Unless noted otherwise herei use the latest edition,Cerro Negro FIREPROOFING OF STRUCTURAL TECHNICAL STANDARD Project ELEMENTS (INCLUDING STEEL VESSEL 22-17-6455 SUPPORTS) Jose Upgrader REV No. 0 | SEP 1997 Page 2 of $ 2.1 Project Specifications ‘J1-6TS-6455 General Specifications for Sellers P41-1D-6455 Fireproofing - General Requirements ‘A12-1N-6455 Ready-Mix Concrete ‘A40-1CS-6455 Concrete Construction Requirements, P42.27S-6456 Field Paint 2.2 American Concrete Institute (ACI) 506.2 Specification for Materials, Proportioning and Applications of Shotcrete, 1990 506.3R Guide to Certification of Shoterete Nozzlemen, 1991 2.3 American Society for Testing and Materials (ASTM) C1440R Standard Practice for Preparing and Testing Specimens from Shotcrete Test Panels, 1904 D790 Test Method for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials, 1992 £605 Test Method for Thickness and Density of Sprayed Fire-Resistive Material Applied to Structural Members, 1993 2240 Test Method for Rubber Property - Durometer Hardness, 1995 2.4 Underwriters’ Laboratories (UL) 1709 (P) Structural Steel Protected for Resistance to Rapid Temperature Rise Fires 2.5 Concrete Reinforcing Stee! Institute (CRS!) CRS! “Manual of Standard Practice", 24th Edition, 1986 3. FIREPROOFING ZONES Areas where fire hazards exist (because of the potential presence of combustibles) will be identified on a plot plan by the Engineer. These areas, called "Fire-Exposed Envelopes" (FES), contain the surfaces that must then be considered for fireproofing application. 4, EXTENT OF FIREPROOFING Detailing the extent of fireproofing on the particuler surfaces within a given FE will chiefly be the task of the discipline commissioned to requisition those surfaces for the project. The extent of fireproofing for surfaces within a particular FE will be indicated on project structural steel drawings, equipment drawings and project lists. Fireproofing requirements for structures, equipment, valves, electrical, and instrument items are noted in Project Specification P41-10-6455, 5. MATERIALSCerro Negro FIREPROOFING OF STRUCTURAL TECHNICAL STANDARD Project ELEMENTS (INCLUDING STEEL VESSEL pooa TS ease SUPPORTS) Jose Upgrader REVNo. 0 | SEP 1997 Page 3 of 8 5.1. Fireproofing materials may be normal cr lightweight concrete, proprietary cementitious fireproofing, intumescent subliming mastics, or insulation materials. Materials shall be in accordance with Project Specification P4i-1D-6458, 5.2 Concrete materials and reinforcement shall conform to Project Specifications A12-1M-6455 and A40-1CS-6455, unless noted otherwise herein. In case Project Specifications A12-1M-6455 and A40-1CS-6455 conflicts with Specification P41-1D-6455, P41-1D-6455 shall govern. Proportions may be adjusted so that minimum compressive strength of both concrete and shoterete shall be 3000 psi (21 MPa) at 28 days, 5.3 Approved proprietary cementitious materials are listed in Project Specification P41-10-6455. The cured material shall have a minimum flexural strength of 340 psi (24 Kg/cm2) per ASTM D 780 and have a Shore D hardness of 35 to 45 per ASTM D 2240, ‘The material shall be applied in a contour configuration for columns and in a box configuration for beams at a one (1) inch thickness, Provide 0.5 inch (13 mm) minimum cover over reinforcing mesh and anchoring studs. 5.4 Any joints between fireproofing and steel where water may enter shall be caulked with Dow Coming 785 or approved equal 6, ANCHORAGE 6.1 Where possible, studs, clips, support angles, or other attachments required by the fireproofing reinforcement shall be made in the fabrication shop before abrasive bast cleaning and coating or galvanizing. Where clips, etc., must be welded to coated surfaces, the area shall be touch-up painted per the project painting specification. 6.2 Fireproofing on skirts shall terminate under a tumed down angle seal welded to the skirt circumference. For insulated vessels, the turned down angle shall be the bottom insulation support ring. For uninsulated vessels, the angle shall be attached to the skirl one (1) inch below the skirt to bottom head weld. 6.3 Lath anchors may be shop-welded pins (such as Nelson Pin Spec 28 Part No. 101-262-075) (or nuts (0.5 inch (12.7 mm) maximum height), or the lath may be anchored to painted structural shapes by the fireproofing applicator with pneumatically driven pins such as Hilti EDN or ENKK types. For flat surfaces such as vessel skirts or column web surfaces greater than 36 inch (810 mm) width, lath anchor studs, pins, or nuts shall be utilized on 12 inch (300 mm) centers in both directions. 6.4 Slab bolsters shall be furnished and attached as shown in Figure 1 forall strucutral members which are to be fireproofed with concrete. Slab bolsters shall be Type SB i accordance with CRS! Bar Support Specification (Chapter 3 of CRSI MSP-2). The size of the slab bolster shall be 3/4 inch (19 mm) for nominal 2 inch (50 mm) thick concrete fireproofing, Other welded attachment devices may be used provided the same dimensions are maintained and the Company's prior written approval is obtained 6.5 The Seller shail fasten the mesh to the anchors before application of fireproofing material. 6.6 For proprietary cementitious fireproofing, galvanized or painted expanded metal lath, as recommended by the material manufacturer, shall be used, Te wire, where required, shall be 18 gauge soft annealed. Lath laps shal be in the web face. Overlaps shall be staggered so there is no more than three (3) layers at any one locationCerro Negro FIREPROOFING OF STRUCTURAL TECHNICAL STANDARD Project ELEMENTS (INCLUDING STEEL VESSEL P22-4 78.6485 Jose Upgrader ae REVNo. 0 | SEP 1997 Page 4 of 8 7. QUALITY ASSURANCE 7.1 Quality Controt 7.1.4. The Seller's quality control/inspection program shall include the necessary measures to assure that completed fireproofing work conforms to the requirements of this Specification and the applicable codes and standards. This plan shall provide for assurance that only accepted fireproofing materials are used, thal inspection of the surface preparation and the fireproofing application is implemented for all phases of work performed, and that records and documentation are prepared and maintained to furnish evidence of compliance with this standard specification and accepted procedures. 7.1.2 The Seller, including any lower-tier organizations engaged by him, shall be subject to surveillance inspection and audit by the Engineer's inspector for compliance with the requirements of this Specification. This surveillance inspection and audit does not relieve the Seller from the responsibilty for conformance to the requirements set forth in the procurement documents, 7.4.3 The Engineer's inspector shall be provided with a detailed schedule and shall be notified of ail required hold and witness points requiring inspection by the Engineer prior to the scheduled date for fireproofing. Failure to provide the required notification may result in the requirement for reinspection or rework, 7.1.4 The Seller's inspector shail identity and document all deviations from the specifications, codes and standards and report these deviations to the Engineer for review and disposition. 7.2 Submittals 7.2.1 The Seller shall submit a listing of all materials to be used in fireproofing and shall identify the specific design mix, including manufacturer's data sheets. The Seller's one (1) hour listed design details shall be submitted for proprietary fireproofing. 7.2.2 The Sellers written procedures for storage, handing, surface preparation, environmental control, application, touch-up and repair, curing, and inspection of the fireproofing system shall be submitted to the Engineer for review and approval. In the event of any conflict, this specification shall prevail 7.2.3. The Seller's proposed fireproofing verification forms for deily inspection records shall be submitted for review and permission to proceed. 7.2.4 A detailed fireproofing verification report, in accepted form, shall be completed each day during the work and shall be submitted for record, ‘The final verification report shall include a statement of completion conformance verifying that the required materials were used and that the accepted application procedures and specifications were followed. The responsible inspector must approve and sign these reports on a daily basis, 7.2.5 The Seller shall satisfactorily install test panels, or samples prior to receiving approval to ‘commence work. Test panels for shotorete shall be in accordance with ASTM C 1140. A test sample 3 foot (one (1) meter) column for proprietary fireproofing shall be used. The panels or ‘samples shall be fireptoofed by each nozzleman qualified for the work. The panel or sample shall be inspected and tested in accordance with Section 7.3, Upon acceptance of all physicalCerro Negro FIREPROOFING OF STRUCTURAL TECHNICAL STANDARD. Project ELEMENTS (INCLUDING STEEL VESSEL P22-47S-6455 Jose Upgrader baila REVNo. 0 | SEP 1997 Page Sof 8 properties, the finish shall be subject to inspection by the Engineer and, if accepted, serve as a Comparator to judge the trowel finish on the work. The finish of the work for all surfaces shall be accepted by the Engineer if they are as smooth as, or smoother than, the comparator. 7.3 Inspection and Testing 7.3.1 Any defects disclosed by inspection shall be re-inspected after correction. Necessary corrective actions for areas which do not meet the requirements of this Specification shall be corrected at Seller's expense. 7.3.2 The surfaces to be fireproofed shall be divided into areas or units of production as a basis for inspection. The inspection points shall be established as follows: Prior to the start of work Following installation of reinforcement materials Immediately prior to application ofthe fireproofing Following the application and curing of the fireproofing eeee 7.2.3 The Seller shall provide on-site inspection. The following tests shall be performed by the Sellers inspector. ‘a. Prior to using compressed alr, the quality of the air downstream of the separator shall be {ested by blowing the air into a clean, white blotter or cloth for two (2) minutes to check for any contamination, oil, ot moisture. This test shall be performed at the beginning and end of each shift and at not less than 4-hour intervals. The test also shall be made after any interruption of the air compressor operation ot as required by the Engineer. The air shall be used only if the test indicates no visible contamination, oil, or moisture. If contaminants are evident, the equipment deficiencies shall be corrected and the air stream shall be retested, Separators shall be bled continuously. Al lines shall be tested individually pricr to use. b. The nozziemen shall be qualified to ACI Guide 506.3. Qualification testing shall be subject to inspection, review and acceptance by the Engineer. . Substrate must be thoroughly cleaned of loose scale, concrete, soot, grease or other materials likely to create voids between the surface to be covered and fireproofing materials. All coating must be intact. Any discrepancies must be rectified before application of the fireproofing d. Anchors shall be randomly tested to ensure sound welds by means of a hammer test. fe. Visual inspection of fireproofing shall be performed to ensure no honeycombing, shrinkage, cracks, mechanical damage, hollow voids, or other defects exist. Observations shall be made to ensure the integrity of caulking and spackling and that the curing membrane was applied, £. Allreinforcement shall be inspected to assure conformance to the required design. 9. Wet thickness shall be measured continuously in accordance with ASTM E 605, before material sets hard. On beams and columns, four (4) sets of random measurements shall be taken for each unit or for each 50 linear feet (15 lineal meters). On beams, the tests shall be made on both flange faces. Dry thickness shall be measured by bore samples of magnetic.Cerro Negro FIREPROOFING OF STRUCTURAL TECHNICAL STANDARD Project, ELEMENTS (INCLUDING STEEL VESSEL 4 i ade P22ATS-6455 Jose Upgrader REVNo. 0 | SEP 1897 Page 6 of 9 gage. h. Proprietary fireproofing hardness shall be determined with a Shore D Durometer, in accordance with ASTM D 2240, after the fire protection coating is fully cured i. The applied fire protection coating shall be free of defects such as excessive cracks, voids, spalls, or any exposure of the substrate. The appearance and workmanship shall conform to the pre-job demonstration surface, 7.3.4 The Seller shall furnish the necessary testing and inspection instruments, properly calibrated and maintained. Such equipment shail be available for use by the Engineer in conducting surveillance of the work, 7.3.5 The following laboratory tests shall be performed and submitted to the Engineer for review: ‘a, Flexural strength tests shall be performed on each batch of proprietary material per ASTM 0790. b. Surface hardness tests shall be performed on each batch of proprietary material per ASTM 0.2240, Batches exhibiting properties below those specified herein shall be unacceptable. . Concrete testing shall be in accordance with Project Specification A12-1M-6455. In addition, random bore samples of gunned and troweled dense and lightweight concrete shall be made at locations selected by the Engineer. Initial bore samples shall be made on the basis of one per each 50 square feet (5 square meters). If the samples meet job requirements, sampling may be increased to one per 100 square feet (10 square meters) subject to Engineer's approval. Repairs shall be made to bored areas using the Seller's recommended procedure. 7.3.6 Defects or damaged areas detected during assembly or handling shall be repaired in accordance with procedures as permitted by the Engineer. 8. INSTALLATION OF FIREPROOFING 8.1 General 8.1.1. The existence of the coating system as specified in project specifications shall be confirmed prior to fireproofing application. All surfaces must be cleaned free from oil or grease. Installation shall be done in accordance with manufacturer's latest published application instructions. Glossy surfaces, loose or flaking paint, or similar surface conitions which would affect adhesion, must be corrected before being covered, 8.1.2 Beam applications shall require the use of galvanized or painted expanded metal lath reinforcement. For beams supporting pipe and grating, the galvanized diamond lath must be ‘wrapped around the flat surface of the bottom beam flange and anchored to the top flange before installing fireproofing. Beams not supporting pipe or grating require reinforcement at both flanges as a minimum, 8.1.3 Column applications for shotcrete or proprietary fireproofing shal! be in accordance with the Engineer's or UL listed (BYBU) contour designs which require the use of galvanized or painted reinforcing metal lath or wire fabric.Cerro Negro FIREPROOFING OF STRUCTURAL TECHNICAL STANDARD Project ELEMENTS (INCLUDING STEEL VESSEL penitence Jose Upgrader Suan: REVNo. 0 | SEP 1997 Page 7 of 9 8.1.4 Flat surfaces such as cylindrical tower skirts, walls, ceilings, decks, and column web areas ‘over 12 inch (300 mm) require the use of galvanized expanded metal lath or wire fabric anchored (on 12 inch (300 mm) centers. 8.1.8 All fireproofing shall be finished relatively smooth through the use of a wood float or trowel using @ full armstroke technique. No special effort shall be made to remove trowel marks. The final appearance shall be relatively smooth, with minimal trowel marks. The finish shall resemble the work sample prepared and accepted by the Engineer as outlined in subparagraph 7.2.6. 8.1.6 Only the recommended or approved types of mixers, pumps, compressors, and other ‘equipment required shall be used to make the installation in accordance with the manufacturer's printed instructions, 8.1.7 The finished fireproofing for lightweight concrete and proprietary materials shall be given ‘two (2) coats of a clear epoxy sealer as approved by the Engineer and the Fireproofing Manufacturer, 8.1.8 Finished surfaces, such as painted walls, floors, exposed ceilings, tile, windows, and in- place equipment shall be protected from damage and over spray. Metal switch boxes, junction boxes, conduits, sprinkler heads, aluminum window, and similar units must be masked to protect from over spray of wet material. 8.1.9 Any over spray or waste shall be removed while still wet and before it has begun to set. Clean-up may be done with scrapers, soapy water, rags, etc. If fireproofing material is allowed to cure before clean-up, it must be chipped or abraded away. The surface shall be restored to the original condition at Seller's expense 8.2 Conerete Concrete fireproofing production, placing and installation shall be in accordance with Project Specification A12-1M-6455. Shotcreting shall be in accordance with ACI 506.2. Typical instaltation details are shown in Figures 1 through 4 8.3 Proprietary Fireproofing 8.3.1 The Seller shall submit a complete installation and inspection procedure and obtain approval of the Engineer/Company before starting any work. 8.3.2 Fireproofing shall be applied between 40°F (4.4°C) and 100°F (37.7°C) ambient temperature with a maximum relative humidity of 5 percent. In dry atmospheres where humidity is low or in warm windy/sunny atmospheres, curing may be accomplished by dampening fireproofing 8.3.3 The manufacturer's printed instructions for sequence of mixing operations and application shall be followed. Material shall be mixed in a shaded area, Material which cannot be applied within the pot life of the material shall be discarded, not retempered or remixed. 8.3.4 The manufacturer's prescribed proportions of fireproofing components, water, mixing time, and temperature and humidity restrictions shall be maintained at all times. Unauthorized ‘modifications will affect the physical characteristics of the cured materials and shall not be allowedCerro Negro FIREPROOFING OF STRUCTURAL TECHNICAL STANDARD Project ELEMENTS {INCLUDING STEEL VESSEL 1 pimen P22-47S-6455 Jose Upgrader REVNo. 0 | SEP 1997 Page @ of 9 % 1% CHAMFER L eagm Ith TT |W or 1 seu 14 — weroeo wine Faaaic SLAB GOLSTER F MELOED WIRE 1 ckawnet SLAB ouster JY coaHreR (re) WELDED WIRE Frente SLAB aoLster PIPE USED AS_4 STRUCTURAL HeNBER 1 cHANrER ay WELDED WIRE FABRIC SINGLE ANCLE, suas socster DENSO STEEWNORK TAPE SENUANT Le DETAIL ‘ 1" pera sr SLAB GOLSTER WELDED WIRE Faseie e WELDED WIRE Faseie channel Stag BoLsTeR. 1 CHER oe SLAB BOLSTER wELOED WIRE FaRie BACK TO BACK. €: TYPICAL CONTINUOUS METAL SLAB BOLSTER (CTatk Weug ‘BOTH LEGS AT EACH END ‘NO EVERY 20 THERES. TD THE. StRoCTURAL MEMBER) FIGURE 1 TYPICAL CONCRETE FIREPROOFINGGerro Negro FIREPROOFING OF STRUCTURAL TECHNICAL STANDARD Project ELEMENTS (INCLUDING STEEL VESSEL oY SUPPORTS) BRATS S88 Jose Upgrader REVNo. 0 | SEP 1997 Page $ of 9 evan Larw stu HERR SAZS TS a af ae de stint Beni over WIRE wearer SEA wine Faeare + by Sseeviow Aca FIREPROOF ING FIGURE 2 FIGURE 3 ‘TOP OF COLUMN FIREPROOFING METAL LATH STUD ON SKIRT make was rReD mat concn ne conenene Fouosrion NOTE WINEAIN 2 FHREPROOFING THDOENESS OVER BOLT cMAIRS FIGURE 4 FIREPROOFING OF VESSEL SKIRTS