Structural Fireproofing

By: J. Gary Cizek, P.E., C.S.P

Baker Engineering and Risk Consultants, Inc.

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Types of Fire Protection What is Fireproofing General Fire Risks Fireproofing Application Fireproofing Inspection Fireproofing Maintenance

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What types of Fire Protection options are available?
Active Fire Protection
Water Sprays Monitors

Passive Fire Protection

Fireproofing Siting Strategies

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Goals of Fireproofing
Help maintain structural integrity of supports and equipment exposed to fires

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Goals of Fireproofing
Shield essential operating systems from fire exposure

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How Fireproofing works
Limits flame spread and fuel load with a high ignition temperature Increase the fire endurance of a material thanks to low thermal conductivity

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To determine usefulness, risk must be assessed
High Fire-Potential Medium Fire Potential Low Fire-Potential

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High Fire-Potential Risk
Large spill of flammable liquid High temperature High pressure

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High Fire-Potential Risk
Examples
Fire Heaters - Corrosive products - Products that can create large spills - Products that can clog piping Flammable liquid pumps rated over 200 gpm history of failures or small piping High pressure reactors Compressors Vessels, HE containing flammables over 600 F Ethylene Units, Catalytic Crackers, Hydrotreaters

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Medium Fire-Potential Risk
Small leaks of flammable liquids High temperature High pressure

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Medium Fire-Potential Risk
Examples
Leaks from instrument or gaskets from accumulators and feed drums Leaks from gauges and gaskets from towers Air-cooled fin-fans heat exchangers Highly automated peripheral equipment (air pre heaters)

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Low Fire-Potential Risks
Any size release of combustible liquids Negligible leaks of highly flammable liquids

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Low Fire-Potential Risks
Examples
Pumps with class IIIB liquid below flash point Piping within battery limits with high concentration of valves, fitting and flanges Flange leaks from heat exchangers

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Fire Scenario
Release mechanism Amount of fuel is released Severity of the fire
- Heat release - Unabated burn time

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Develop a fire scenario envelope

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Determine appropriate protection rating

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Fireproofing application
Locations requiring Fireproofing Multilevel equipment structures and bracings

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Fireproofing application
Locations requiring Fireproofing
Pipe racks and supports/aircoolers

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Fireproofing application
Locations requiring Fireproofing
Tower, vessel supports

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Fireproofing application
Locations requiring Fireproofing - Instrument, hydraulic and power cable trays - Emergency valves

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Fireproofing materials
Concrete Based

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Fireproofing materials
Dense Concrete
Advantages
- Can withstand thermal shocks and hose streams - Can withstand flame impingement up to 2000F - Easy application - Performance extensively proven (4 hrs protection)

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Fireproofing materials
Dense Concrete
Disadvantages
- High weight - High Thermal conductivity - Installation costly and time consuming

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Fireproofing materials
Lightweight Concrete
Advantages
- Lightweight material - Better Fire protection properties than dense Concrete - Durable and low maintenance - Can withstand flame impingement up to 2000F - Can withstand thermal shocks and hose streams - Easy to install

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Fireproofing materials
Lightweight Concrete
Disadvantages
- Porous material - Moisture absorption leads to cracking and spalling in freezing climates - Need to maintain sealing coating - Susceptible to mechanical damage

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Fireproofing materials
Subliming, Intumescent and Ablative Mastics

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Fireproofing materials
Subliming, Intumescent and Ablative Mastics
Advantages
- A quick application - Lightweight - Suitable for use on existing supports that may not handle additional weight

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Fireproofing materials
Subliming, 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

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Fireproofing materials
Intumescent Epoxy Coating
Advantages
- Excellent bonding and corrosion protection - Lightweight and durable under nonfire conditions - Flexible and tolerates vibration -Can have good durability in sever jet fire conditions

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

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Fireproofing materials
Spray Applied lightweight Cimentitious Fireproofing
Advantages
- Lightweight - Vermiculite allows for denting instead of cracking or shattering

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Fireproofing materials
Spray Applied lightweight Cimentitious Fireproofing
Disadvantages
- Properties vary greatly with composition - Not suitable for high vibration areas - Great care must be taken to ensure proper application thickness

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Fireproofing materials
Preformed Inorganic panels

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Fireproofing materials
Preformed Inorganic panels
Advantages
- Clean application - No curing time - Low thermal conductivity

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

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Fireproofing materials
Masonry blocks or bricks
Advantages
- Easy Installation - lightweight

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Fireproofing materials
Masonry blocks or bricks
Disadvantages
- High Installation costs - High maintenance - Admits moisture and cracks

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Fireproofing materials
Endothermic Wrap
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

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Fireproofing materials
Endothermic Wrap
Disadvantages
- Must be weatherproofed when used outdoors - Weatherproofing must be done with manufacturers specified protection tape to preserve recommended protection

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Fireproofing Inspection
Survey coatings for
Surface cracks delamination, rust stains, or bulging Weathering

Selectively remove samples to examine conditions underneath, promptly repair sample area

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Fireproofing Inspection
Coat spare pieces of steel during application for further fire testing Inspect after maintenance to ensure fireproofing has been replaced

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Fireproofing maintenance
Repairs needed when more than hairline cracking appears Repairs needed when bulges, represent loss of bonding, appear

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Fireproofing maintenance
When Bonding failure is apparent Remove fireproofing Clean structure Prime structure Reinstall fireproofing

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Fireproofing maintenance
Consult with manufacturer to determine when surface coating should be renewed.

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Conclusion
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