K61 EPOXY CASTINGS FOR FIRE PROTECTION OF STEELWORK

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Epoxy intumescent castings for use as a high performance, durable and highly decorative solution for fire protection to columns and beams offering up to 3 hours fire protection externally and internally.

A robust, maintenance free all-weather system for mixed use developments, supermarkets, schools, offices, iconic buildings and where high people traffic and/or environmental requirements demand a robust system which is easy to maintain.

To be read with Preliminaries/General Conditions.

INTERACTIVE FIRE PROTECTION SYSTEMS

001 PRIMER TO SUIT THE INSTALLATION TO STEEL COLUMNS AND BEAMS

Use/location: Steel sections where castings are required
Preparation: G10 (SA 21/2)
Primer:
- Type: 2 pack epoxy zinc phosphate primer
- Manufacturer: International Paint
- Product reference: Intergard 251
- Dry film thickness: 75 microns

002 DIRECT FIXING OF CASTINGS TO HOT ROLLED HOLLOW SECTIONS

Use: Circular and rectangular hollow sections
Intumescent castings: Direct application with adhesive to hollow sections
Orientation: Beams/Column
Location: Internal/External
Manufacturer: Interact Fire Solutions Limited 01694 751394
- Product reference: Interactive Columns
- Fire resistance to BS476-21: (Enter fire protection period (90 minutes)
Finish: Very high decorative

003 FIXING TO FABRICATED HOLLOW SECTION

Use: For use where the fabrication does not allow for continuous adhesion to the entire column/beam surface
Intumescent castings: Partial fixing with adhesive to hollow sections with the casting spanning the recessed faces
Orientation: Beams/Column
Location: Internal/External
Manufacturer: Interact Fire Solutions Limited 01694 751394
- Product reference: Interactive Hybrid
- Fire resistance to BS476-21: (Enter fire protection period (90 minutes)
Finish: Very high decorative

004 FIXING TO UNIVERSAL BEAMS AND UNIVERSAL COLUMNS

Use: Universal beams and columns
Intumescent castings: Partial fixing with adhesive to sections with the casting spanning the web faces
Orientation: Beams/Column
Location: Internal/External
Manufacturer: Interact Fire Solutions Limited 01694 751394
- Product reference: Interactive Hybrid
- Fire resistance to BS476-21: (Enter fire protection period)
Finish: Very high decorative

005 SECONDARY CLADDING TO COLUMNS

Use: Decorative circular cladding to universal columns and universal beams as columns - other shapes available subject to design.
Intumescent castings: Free standing casings providing 100% fire integrity over universal columns and universal beams as columns
Orientation: Column
Location: Internal/External
Manufacturer: Interact Fire Solutions Limited 01694 751394
- Product reference: Interactive Casing
- Fire resistance to BS476-21: (Enter fire protection period)
Finish: Very high decorative

06 HIGH PERFORMANCE TOP COAT FOR INTERNAL AND EXTERNAL CONDITIONS

Manufacturer: International Paint
Product reference: Interfine 979 polysiloxane or Interthane 878 polyurethane
Minimum period to first maintenance
- Polyurethane / semi gloss = 8 years
- Polysiloxane / high gloss = 20 year
Undercoat if required with compatible primer
Dry film thickness: Refer to top coat manufacturer’s details
Colour: (Enter colour reference) Minimum of two coats roller/spray applied

007 DOMESTIC TOP COAT FOR INTERNAL CONDITIONS ONLY

Manufacturer: Dulux or similar approved
Product reference:
- Oil based wood primer - Specify
- Suitable undercoat - Specify
- Selected finish coat - Specify
Dry Film thickness: Refer to top coat manufacturer’s details
Colour: (Enter colour reference) Minimum of two coats roller/spray applied

GENERAL REQUIREMENTS

008 ENVIRONMENTAL CAPABILITIES

Withstands class C5-1 (industrial) environmental conditions as laid down under EN ISO 12944-2 1988
Withstands pooling water
Withstands cascading water
Is suitable for near shore environments fully exposed
Refer to Interact Fire Solutions for environmental table EN ISO 12944-2 1988

009 ADHESIVE

Where applicable Interactive Columns (direct fixing) or Hybrid
Manufacturer: International Paint
Reference: Interchar 212
Thickness: 2 mm
Application: 8 mm tile trowel
Spread to provide sufficient thickness to achieve 2 mm overall coverage
Coverage contact to be no less than 92.5% of the surface area of the steel

010 JOINT FILLER

Primary Filler:
- Where applicable Interactive Columns (direct fixing), Hybrid, Interactive Casings (secondary cladding)
- Manufacturer: International Paint
- Reference: Interchar 212
- Thickness: Nominally 6 mm x thickness of the casting (8 mm)
- Application: Trowel
- Ensure material is compressed into joint to ensure 100% margin contact
Secondary (decorative) Filler:
- Where applicable Interactive Columns (direct fixing), Hybrid, Interactive Casings (secondary cladding)
- Manufacturer: Isopon or similar approved
- Reference: Two pack epoxy filler
- Application: Fill all deformation and pin holes to produce a smooth and uniform finish

011 VALIDATION OF MATERIALS

Project specific evaluation of intumescent casting materials
Standard: To BS 8202-2 clause 4
Submit on request
- Conformance documents showing batch numbers
- Material control document detailing ratios
- Visual inspection report

012 WORKING PROCEDURES

Standard: To BS 8202-2
Give notice: Before commencing surface preparation and casting installation
Quality control: record project specific procedures for surface preparation and coating application

013 WORKING CONDITIONS

General: Maintain minimum environmental conditions
- Temperature 5ºC
- Humidity 85%
- Dew point 2ºC above
Preparation of Surfaces
- Clean and dry at time of installation
- Lightly abrade
- Galvanised Steelwork
- Degrease
- Lightly abrade
- T wash (mordant)
- Ensure all galvanised surfaces have been etched and changed colour to a dark grey

014 APPLICATOR’S PERSONNEL

Operatives: Manufacturer’s approved installers only
Evidence of training/experience and approval : submit on request

015 CONTROL SAMPLES

General: as required - carry out sample areas of finished work as follows:present benchmark, uininstalled sample.
Approval of appearance: as required - obtain before commencement of general casting installation

016 INSPECTION

The subcontractor must complete the quality record sheet
- Permit intumescent casting manufacturer to:
  - inspect environmental documentation
  - inspect work in progress
  - inspect quality control records
  - take measurements to establish contact area
  - Intumescent casting manufacturer’s inspection reports:
  - Submit to main contractor
  - Secure receipt from main contractor
  - Provide a signed copy for manufacturer

APPLICATION OF COATINGS

017 INTUMESCENT COATING THICKNESS

Required thickness of casting:
- Determine for every steel member to give specified period of fire resistance
- Secure casting manufacturer’s written assurance and validate if required against raw material manufacturer’s standard details
Schedule and drawings
- Submit at least two weeks before starting work
Schedule content:
- Member sizes, weights/thicknesses
- Loading conditions
- Show variant of the exposed perimeter
- Sectional area (Hp/A) ratio
Drawing content
- Steelwork drawings marked in colour to show required thickness for each member
Special Details
- Check that the casting manufacturer has specific test data
- Secure a record of the specific test data or assessment from an independent authority
- A raw material manufacturer’s assurance is not acceptable

018 MEASUREMENT CASTING THICKNESS

Casting thickness
- Check the certificate of conformity supplied by the casting manufacturer complies with the required fire protection period.

019 HIGH DECORATIVE FINISH

Definition: high standard of evenness, smoothness and gloss when viewed from a distance of 2 metres or more.
No pin holing
No runs
No undulation or tram-marking which may show when down lighters are installed
A sample of the finish is to be presented to the client prior to progressing with the finished coats
Vertical lighting must be used for inspection when down lighters are to be used as part of the building design
Horizontal lighting must be used for inspection when general lighting is used as part of the building design
All joints are to be filled to a high standard leaving no evidence of jointing

020 TOP SEALER COAT

Roller/spray apply
Application: to achieve dft recommended by manufacturer and to give an even, solid, opaque appearance, free from runs, sags and other visual defects.

021 RECORDS OF COATED STEEL

On completion of intumescent casting installation work, submit:
- Accurate surface preparation and coating application records
- Fire resistance certificates
- Intumescent casting manufacturer’s recommendation for maintenance and overcoating

022 MAINTENANCE

The system is maintenance free for up to 20 years with the exception of physical damage
The system does not require periodic inspection to meet the warranty requirements
Over-coating can be with any compatible material and is not subject to the manufacturer’s prior approval
Repairs to physical damage must not be visible
A two pack filler, or a single pack filler where a non-performance coating is used, must be suitable for the system

023 OTHER BENEFITS

Cast epoxy intumescent has sound insulation properties which my comply with the accoustic requirements of the building.
The casings have a high standard of impact resistance.

Note:

This information is offered in good faith but without guarantee or liability. In cases of doubt, users should consult with the relevant authority.

Interact Fire Solutions Limited states that the information given herein is supplied for your guidance only and is based upon the results of controlled tests and experience obtained in the application of the product.

As the supplier only Interact Fire Solutions Limited has no control over the method or conditions of application of the product and consequently no warranties expressed or implied are intended to be given as to the coverage or performance of the products mentioned or referred to herein and no liability will be accepted for any loss, damage or physical injury resulting from the use or application of the information, data or products mentioned or referred to herein