CONCRETE FIREPROOFINGCONCRETE FIREPROOFING
ANALYSIS, EVALUATION AND
REPAIR STRATEGIES
ANALYSIS, EVALUATION AND
REPAIR STRATEGIES
April 12
16 2010
April 12
16 2010
April
12
-
16
,
2010
League City, Texas, USA
April
12
-
16
,
2010
League City, Texas, USA
Picture Courtesy of Refinery Terminal Fire Company (RTFC)
Thomas R. Kline [email protected] 281.479.0391
Fireproofing PurposeFireproofing Purpose
Maintaining structural
stability and integrity of
steel members and
vessel/pipe supports for a
defined period of time
when exposed to a fire
Protection
Active
Passive
Active
Passive
Picture Courtesy of Refinery Terminal Fire Company (RTFC)
2
Fireproofing BasicsFireproofing Basics
Material
minimum
thickness
Restrict heat
transfer rate
Protected
element
Acceptable steel
core temperature at
the end of fire
exposure to avoid
collapse/buckling
3
Comparison of Typical ‘Hydrocarbon’ and
‘
Cellulose
’
Time
-
Temperature Curves
2500 1400
Hydrocarbon
Cellulose
Time
Temperature
Curves
2000
1000
1200
it (°F)
s
(°C)
Cellulose
Hydrocarbon
1500
800
F
ahrenhe
e
s Celsiu
s
minutes
1000
400
600
D
egrees
F
Degre
e
0
500
0
200
D
0
02040
60
80
100
120
0
Minutes
4
Effect Of Temperature On Strength Of
Structural Steel
100
Structural
Steel
80
rength
60
riginal St
50% reduction
@ 1000
°
F
40
c
ent of O
@
1000
F
20
Per
c
0
50 300 550 800 1050 1300 1550
Degrees Fahrenheit (°F)
5
Fire And Explosion Behavior
Resistance to thermal and erosive forces
Surface temperature of substrate
Non-combustible
Withstand effects of explosion and subsequent
drag pressures
Picture Courtesy of Refinery Terminal Fire Company (RTFC)
6
Pre-Fire Durability
Weather cycling and chemical tolerance
V
apor permeability and low porosity
Vibration resistance - compressive, tensile and
flexural strength
Hardness value and impact resistance
Abrasion and erosion resistance
Bonding strength
Bonding
strength
Wash-down resistance
7
Passive Fireproofing Materials
CEMENTITIOUS
Lightweight
D
¾ Heat absorbers
¾ Hard and durable
¾
Economic
D
ense
Epoxy
¾
Economic
¾ Easy to install and repair
¾ React under fire and emit
g
ases
INTUMESCENT
Epoxy
based
g
¾ Form a low density carbonaceous
char
FIBROUS
Boards
Blankets
¾ Can provide thermal insulation
¾ Absorb water
¾ Indoor applications
COMPOSITES
Blankets
Com
p
osite
¾ Sandwich of metallic cladding,
cementitious board and mineral
COMPOSITES
p
Panels
cementitious
board
,
and
mineral
or ceramic fibers
¾ Not economically feasible
8
Cementitious Concrete Materials
Made with Portland cement or modified fire-
resistant cements
Specific weights
y Dense concrete - 140 to 150 lb./ft
3
Li ht i ht t
25 t 80 lb /ft
3
y
Li
g
ht
we
i
g
ht
concre
t
e -
25
t
o
80
lb
.
/ft
3
Thermal conductivity tends to be inversely
proportional to specific weight
proportional
to
specific
weight
Capable of withstanding direct flame
impingement up to 2000
o
F (1100
o
C)
impingement
up
to
2000
F
(1100
C)
Alkaline passive film protects the embedded
steel
9
Intumescent Epoxy Coatings
Intumescent coatings react to flame or heat at
around 300
o
Fahrenheit (149
o
C) by expanding
i t thi k lti ll l i l ti bl k t Thi
i
n
t
o a
thi
c
k
mu
lti
ce
ll
u
l
ar
i
nsu
l
a
ti
ng
bl
an
k
e
t
.
Thi
s
intumescent carbonaceous foam sharply limits
the spread of flame and insulates the steel.
the
spread
of
flame
and
insulates
the
steel.
Washable, aesthetically pleasing, mark resistant
surface like traditional
p
aint
p
Provide protection from corrosion
Require expertise in application and controlled
Require
expertise
in
application
and
controlled
conditions
Com
p
arativel
y
hi
g
her cost to cementitious
pyg
materials
10
Fireproofing Rating
A function of:
Time and ease of evacuation
Fire hazard
p
osed b
y
substance
py
Fire suppression capabilities
2 inches (50 mm) of
cementitious products will
cementitious
products
will
provide a 2-hour rating
(
BS476 & ASTM E-119
)
(
)
11
Concrete Fireproofing In
Processing Units
Multilevel Equipment
Multilevel
Equipment
Structures
Pipe Racks
12
Fireproofing Deterioration
CorrosionCorrosion
Cracking
Risk Of Loss Of
Fi P t ti
Fi
re
P
ro
t
ec
ti
on
Efflorescence
Fire Damage
13
Embedded Structural Steel
Corrosion Exposed During
Fireproofing Inspection
Fireproofing
Inspection
Process
14
Rust Stains Emerging From
Fireproofing Indicating
Fireproofing
Indicating
Early Evidence Of Steel
Member Corrosion
Failed Fireproofing Due To
Embedded Structural Steel
Member Corrosion
15
Improperly Detailed
Improperly
Detailed
Cementitious
Fireproofing, Notice
No Mesh
Reinforcement
Reinforcement
16
Severely Corroded
Embedded Wire
Mesh And Corroding
Mesh
And
Corroding
Structural Steel
Member Flanges
Severel
y
y
Corroded
Embedded Wire
Mesh And
Corrodin
g
g
Structural Steel
Members &
Connections
17
Fireproofing Deterioration Fireproofing Deterioration
MechanismMechanism
Corrosion
Corrosion-
Induced
Corrosion
Products
Delamination
/
Spalling
Induced
Cracking
Structural Steel
Cementitious
Structural
Steel
Beam/Column
Fireproofing
Surface
Corrosion
Shrinkage
Crackin
g
Corrosion
Products
g
18
Fireproofing Deterioration
()
Fireproofing Deterioration
()
Mechanism
(
cont.
)
Mechanism
(
cont.
)
Structural Steel
Structural
Steel
Beam/Column
Preformed
Inor
g
anic Panel
g
Fireproofing
Open Areas Within The “Boxed”
St t l M b Fill With M i t
Corrosion
St
ruc
t
ura
l
M
em
b
er
Fill
s
With
M
o
i
s
t
ure
And Promotes Corrosion
Products
19
Prior Repair
Shrinkage Cracked
And Pipe Slide
And
Pipe
Slide
Shoe “Seized” By
Corrosion
20
Fireproofing Deterioration
()
Mechanism
(
cont.
)
PIPELINE
C i B ild
U
Structural Steel
Co
rr
os
i
o
n
C
orros
i
on
B
u
ild
-
U
p
Frozen Slide
Cementitious
Fireproofing
Co os o
Rotation
St t l St l
Fireproofing
St
ruc
t
ura
l
St
ee
l
Beam/Column
Rotation
21
Condition Survey And
Evaluation
Assess the condition of concrete
fireproofing
fireproofing
Evaluate causes of concrete/steel
distress
distress
Provide conceptual repair
recommendations
22
Need For Fireproofing
Safety
Possible structural collapse
Restoration
y
Possible
structural
collapse
y Reduced fire
protection/lower expected
performance
y Personnel at risk due to
falling debris
falling
debris
Insurance costs
Aesthetics of
Aesthetics
of
damaged/falling
fireproofing
fireproofing
23
Visual Inspection And Mapping
Note: Excavation at crack locationNote: Excavation at crack location
24
Excavation Geometry
St t l
St
ruc
t
ura
l
Steel
element
Reinforcing
wire mesh
Structural
Steel Beam
Fireproofing
Fireproofing
25
Ultrasonic Thickness
Measurements
Ultrasonic Thickness
Mt
Ultrasonic Thickness
Mt
M
e
t
er
Structural steel pipes,
bdb
M
e
t
er
Structural steel pipes,
bdb
we
b
s an
d
b
eams
flanges
Aidf
we
b
s an
d
b
eams
flanges
Aidf
A
ccess one s
id
e o
f
steel member
A
ccess one s
id
e o
f
steel member
26
Measurement Analysis
Wide Flange
Flange
Section
Wide
Flange
Shape
Flange
Thickness t
f
Section
Loss (%)
Theoretical
Measured
vs
If critical,
remedial actions
t
w
t
f
needed before...
27
Conceptual Fireproofing Repair
Assemble scaffolding for elevated regions
of distressed fireproofing
Assemble scaffolding for elevated regions
of distressed fireproofing
of
distressed
fireproofing
Remove deteriorated concrete fireproofing
and wire mesh avoiding damage to
of
distressed
fireproofing
Remove deteriorated concrete fireproofing
and wire mesh avoiding damage to
and
wire
mesh
avoiding
damage
to
structural steel members
Clean exposed embedded structural steel
and
wire
mesh
avoiding
damage
to
structural steel members
Clean exposed embedded structural steel
Clean
exposed
embedded
structural
steel
members of corrosion products
Inspect members and connections for
Clean
exposed
embedded
structural
steel
members of corrosion products
Inspect members and connections for
Inspect
members
and
connections
for
structural integrity
Coat exposed structural steel section
Inspect
members
and
connections
for
structural integrity
Coat exposed structural steel section
Coat
exposed
structural
steel
section
Coat
exposed
structural
steel
section
28
Fireproofing Repair (Cont.)
Install wire mesh
Abl t
ti ht it f k
Install wire mesh
Abl t
ti ht it f k
A
ssem
bl
e mor
t
ar-
ti
g
ht
cav
it
y
f
ormwor
k
Re-establish the cementitious fireproofing
ti b i “f d ” l t
A
ssem
bl
e mor
t
ar-
ti
g
ht
cav
it
y
f
ormwor
k
Re-establish the cementitious fireproofing
ti b i “f d ” l t
sec
ti
on
b
y us
i
ng
“f
orm an
d
pour
”
p
l
acemen
t
techniques
Rf kftiidd
sec
ti
on
b
y us
i
ng
“f
orm an
d
pour
”
p
l
acemen
t
techniques
Rf kftiidd
R
emove
f
ormwor
k
a
ft
er cur
i
ng per
i
o
d
an
d
surface grind cementitious repairs to match
original fireproofing surface contours
R
emove
f
ormwor
k
a
ft
er cur
i
ng per
i
o
d
an
d
surface grind cementitious repairs to match
original fireproofing surface contours
original
fireproofing
surface
contoursoriginal
fireproofing
surface
contours
29
Valuable Repair Aspects
Turnkey investigation
Attention to details
Bud
g
etin
g
ca
p
abilities
ggp
Corrosion protection to steel
Production rates
Production
rates
Adjustable crew size with qualified personnel
Hi h lit i t i l
Hi
g
h
qua
lit
y repa
i
r ma
t
er
i
a
l
s
Observe standard industry practices
30