< Security Level 2 > 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

01.06.09

For Bid Enquiry

UCM

PRK

SSV

Rev. no.

Issue Date

Description

Prepared by Checked by Approved by

TOYO ENGINEERING INDIA LIMITED

MUMBAI INDIA

< Security Level 2 > Sheet 2 of 11

Revision History Rev. A Date 01.06.09 Description For Bid Enquiry

< Security Level 2 >

FIRE PROOFING OF STEEL STRUCTURE

HPCL, Visakh ISSUED : 29.12.2008 DOC.No: A-320
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 DHT PROJECT

Sheet 3 of 11

CONTENTS

SR. NO. 1.0 2.0 3.0 4.0 4.1 4.2 5.0 5.1 5.2 6.0 7.0 8.0 9.0 10.0 11.0 SKETCH-1 SKETCH-2 SKETCH-3 SCOPE

DESCRIPTION

PAGE NO. 4 4 4 4 4 4 5 5 5 5 5 6 6 7 8 9 10 11

APPLICABLE CODES PRIORITY OF REQUIREMENTS GENERAL Purpose Fire Resistance Rating CRITERIA OF FIRE PROOFING Pipe Racks Equipment Supporting Structures SURFACE PREPARATION FIRE PROOFING BY GUNITING FIRE PROOFING BY IN-SITU CONCRETE (ENCASING) VERMICULITE CEMENTITIOUS COATING APPLICATION SKETCHES FOR FIRE-PROOFING DETAILS CONCRETE FIRE-PROOFING TO BEAMS & BRACINGS CONCRETE FIRE-PROOFING TO COLUMNS MISCELLENEOUS DETAILS

< Security Level 2 >

FIRE PROOFING OF STEEL STRUCTURE

HPCL, Visakh ISSUED : 29.12.2008 DOC.No: A-320
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 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 IS 6433 - 1972 IS 9012 - 1978 : Hard drawn steel wire fabric for concrete reinforcement. : Specification for guniting equipment. : 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) (2) (3) Special conditions This specification Codes

4.0 4.1

GENERAL 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 ISSUED : 29.12.2008 DOC.No: A-320
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 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 5.1

CRITERIA OF FIRE PROOFING 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 6.1 SURFACE PREPARATION 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. 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. FIREPROOFING BY GUNITING 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

6.2

7.0 7.1

< Security Level 2 >

FIRE PROOFING OF STEEL STRUCTURE

HPCL, Visakh ISSUED : 29.12.2008 DOC.No: A-320
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 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. 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. The finish shall be wooden float or sponge trowelled sufficient to obtain a uniform appearance without attracting excessive laitance to the surface. 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.

7.3

7.4 7.5

7.6

Shotcrete thus applied shall develop not less than 24 N/mm compressive strength in 28 days. All outside edges of fire proofing shall be chamfered / rounded off by 20mm. 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. 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. 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. The mixing shall be made in concrete paddle blade mixers in accordance with the manufacturers instructions. The water added shall be of potable quality. 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. FIRE PROOFING BY IN-SITU CONCRETE (ENCASING) Concrete for fire proofing shall be M20 grade. Mixing and placing shall be done as per TEIL specification no. A-318. Minimum thickness of concrete coating over the steel shall be 50 mm.

7.7 7.8

7.9

7.10 7.11 7.12 8.0 8.1

8.2

< Security Level 2 >

FIRE PROOFING OF STEEL STRUCTURE

HPCL, Visakh ISSUED : 29.12.2008 DOC.No: A-320
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 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. VERMICULITE CEMENTITIOUS COATING Design Specifications :

9.0 9.1

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. 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. The coating material shall be easily repairable and shall be durable. Application procedure of the coating shall be non hazardous, shall not interfere with the working of adjoining areas and shall be easy. 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. APPLICATION

9.1.3

9.1.4 9.1.5

9.1.6

10.

Vermiculite cementitious coating shall be mixed with water in a suitable mixer or on clean platform as per manufacturers 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 manufacturers 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 ISSUED : 29.12.2008 DOC.No: A-320
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 DHT PROJECT

Sheet 8 of 11

The full specified thickness shall be developed in three successive coats. Initial Coat Intermediate Coat : : Thickness between 8 mm to 12 mm. Thickness between 18 mm to 22 mm to give total thickness of 30 mm upto Intermediate coat. Not less than 8 mm thick.

Final Coat

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 ISSUED : 29.12.2008 DOC.No: A-320
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 DHT PROJECT

Sheet 9 of 11

SKETCH-1

< Security Level 2 >

FIRE PROOFING OF STEEL STRUCTURE

HPCL, Visakh ISSUED : 29.12.2008 DOC.No: A-320
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 DHT PROJECT

Sheet 10 of 11

SKETCH-2

< Security Level 2 >

FIRE PROOFING OF STEEL STRUCTURE

HPCL, Visakh ISSUED : 29.12.2008 DOC.No: A-320
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 DHT PROJECT

Sheet 11 of 11

SKETCH-3 MISCELLENEOUS DETAILS