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(Last figure of DIBt document is missing. I keep asking but they won't send it to me.)

Translation of 'Approval Guidelines for Reactive Fire Protection Systems on Structural Steel Building Components' dated November 1997 published by Deutsches Institut für Bautechnik (DIBt), Berlin, Federal Republic of Germany.

(original Title: Zulassungsgrundsätze für reaktive Brandschutzsysyteme auf Stahlbauteilen, Fassung November 1997)

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Achim HeringTranslator's Notes

This preamble is lengthy, but the rest of the document may be confusing or misleading without understanding the contents of the preamble.

Note: Technical translations must strike a balance between accuracy of the reflection of the original document as well targeting the resulting document to a readership in the most comprehensible manner. In this endeavour, the translator has at times inserted explanatory text in parentheses as well as changed sentence structure. German technical documents tend to contain sentences as long as your arm. Some of these have been cut down to bite-sized chunks. Also, the reader must bear in mind that terms deemed as correct translations in any number of dictionaries may deviate vastly from industry jargon in various countries. Typically, governmental and standard documents steer clear of industry jargon. But when the official terms of one English speaking country vary from those of another for the identical item, which happens all the time, confusion can result. There are several such examples in this very document. This is why this page is very heavily linked to other pages from website of the translator, as well as other sources, in an attempt to increase comprehension and reduce confusion.

This comprehensive set of test procedures can be partly applied to non-intumescent materials as well. For the test methods published by DIBt, which are dedicated to intumescents, other than spray applied fireproofing  for structural steel, please click here: http://www.oocities.org/ghering2000/dibt.html. The procedure on this page originated in the Federal Republic of Germany. By law, Germany clearly differentiates between building materials (for instance the caulking if a firestop system, on its own, would be a "material" of "Baustoff") and building components (the caulking, together with the packing and the penetrant and the fire separation would be a "component" or "Bauteil"). Each have separate requirements. In this particular test method, material testing (Baustoffprüfungen) is included in the system testing (Bauteilprüfungen). Thus, intumescents are treated the same way any other "reactive" products are treated in order to obtain a fire-resistance rating. The concept is that if a chemical and physical reaction of the building material is necessary in order for it to perform its basic function, DIBt mandates that proof be submitted that this reactive function actually work long-term, as without that, no protection can be expected.

The symbol "§" means paragraph.

Germans use the term intumescent. In German, it is spelled intumeszent. However, official government documents, such as the standard translated herein, don't use the word 'intumeszent'. Perhaps this is because the term itself is hard to find in common dictionaries or spell checkers, as opposed to manufacturers' literature and trade magazines. The original German document, upon which this English translation is based, utilises the term 'Dämmschichtbildner', which roughly (or directly) translates to "creator of a layer of insulation". This term, however, is not entirely descriptive of all intumescents, by definition, which may indeed swell and thus increase their volume and decrease their density. The term 'Dämmschichtbildner' is most applicable to thin film intumescents, which create a soft foam, which envelops a substrate  as in spray applied fireproofing, or the interior of certain firestop pillows. However, the term is hardly descriptive of certain high strength, high pressure and lower volume intumescents, such as are used at times in plastic pipe firestop devices utilising sodium silicates and graphite. The latter intumescents, on their own, don't always create a uniform layer of insulation, which would not be defeated by convection. This is because they do not undergo a uniform bubbling process, or a 'liquid stage' and thus are also less endothermic. However, since ALL intumescents, high strength and low strength must be tested the same way (if they are to be marketed in Germany that is), the translation will use the term 'intumescent', as opposed to "creator of a layer of insulation", or the previous edition's version "materials that foam up under the influence of fire".

Also, the reader (you) may get the impression that the German laboratories, who utilise this guideline, may be given a significant amount of latitude in terms of their potential abilities to deviate from from the procedures outlined in this document if warranted due to particular product characteristics, which may make strict adherence to this standard impractical or result in unreliable data. One must, however, bear in mind, that a report from a DIBt accredited laboratory only forms the basis for an application for approval by DIBt. In fact, the bottom of the report contains a mandatory and cautionary statement, indicating that the sole purpose of the report is to provide data to supplement an application for approval by DIBt. The report thus has no validity in the field minus an accompanying and current DIBt approval. Once this request is received by DIBt, there is still the matter of convincing the SVA expert committee (which meets several times per year in Berlin) that what was done is proper and worthy of the approval. The translator has seen one case, where field data was submitted to DIBt, in connection with a delamination issue of a spray applied fireproofing. DIBt almost immediately imposed further restrictions on the vendor's approval to account for what had been found in the field and did not revert the approval back to the original state until sufficient data had been produced to prove beyond the shadow of a doubt that the problem was inadequate surface preparation (oily substrate), preventing a proper bond, thus acquitting the product.

Also, in fireproofing of structural steel (beams and columns), since one cannot expect to test every available profile type, so-called profile factors are in use worldwide, which allow the use of calculations in order to determine coating thicknesses of beams and columns. The German designation for the profile factor is U/A. The Canadian designation is M/D. The US designation is W/D. Here is how one may convert from one to the other:

U/A = 1/m or m`¹

(Note: m`¹ is "m to the power of negative 1". The translator did not have an html key for the "negative" symbol in uppercase; ergo the jury-rig)

U = Umfang (or circumference). It refers to the circumference of the steel beam or column, which is exposed to fire in m²/m or square metres per lineal metre, which is the same as the circumference in metres. U, just like D in Canada or the US, = the perimeter of protection, at the interface of the protection material and the steel through which heat is transferred to the steel. Thus, it is imperative to know whether one is protecting a column (4-sided exposure) or a beam (3-sided exposure). Another important factor is whether the protection afforded the steel member follows the contour of the steel or consists of a box around the outside of the steel beam or column and whether the box fits snugly or there may be a clearance. The inner box perimeter is the important dimension here. This goes for both sides of the Atlantic.

A = Area (Yes, they use the English term for that over there.) in m² (Note, Cdn. Steel Tables use mm²!)

By contrast, in Canada we use M/D:

M/D = (kg/m)/m

M = Mass in kg per lineal metre

D = Area, which is exposed to fire in m²/m or square metres per lineal metre.

In the US, the same approach applies as in Canada, except that the unit of measure is Imperial, as opposed to metric and what is really mass is referred to as "weight", even though it is expressed in pounds, as opposed to Newtons.

Thus, W = lb/ft or pounds per lineal foot. 1kg = 2.205lbs.

D = U

Since steel has the same density, whether used or made in Germany or Canada, it follows that the conversion from one to another involve the density of steel, which, for the purpose of this document, and steel tables available to the translator from Germany and Canada, is 7.85 (kg/L) or a density of 7,850kg/m³.

Therefore:

M/D = C for Canadian

U/A = G for German

G = 7850 ÷ C

Thus, for the Canadian profile W610x241, M/D = 109 and U/A = 72

Also, there are several references to DIN4102. DIN4102 is a large, multi-component standard, which includes all German fire testing requirements, from combustibility, to flame-spread, fire-resistance ratings, as well as a catalogue (part 4) of "old" systems, using very common generic materials, such as concrete, home-made vermiculite plasters, steel, etc. Part 4 of DIN4102 is very similar to the appendix to the National Building Code of Canada, which depicts generic systems or designs for obtaining fire-resistance ratings, based on testing done at the National Research Council of Canada. As a result, Germans differentiate between "old" systems and "new" systems, whereby the "old" ones are listed in Part 4 of DIN4102 and the "new" ones would be those approved by DIBt. Obviously, the "old" ones do not require separate approval. Since generic materials are used, one must simply follow the printed directions in order to obtain a rating, very much like our National Building Code of Canada Appendix.

Also, Germans classify fire-resistance durations with alphanumerical designations. F90 = 90 minute fire-resistance rating, whereas T90 would be a 90 minute fire-protection rating for a fire door or S90 would be the same thing for a cable penetration firestop.

Also, the original text document contains a total of 14 footnotes, which are translated and provided herein between the text and the figures. Footnote numbers are shown here in parentheses, such as (1) for Footnote 1 or (5) for Footnote 5.

Also, while the original text utilises parentheses, whose contents bring clarity to the document, some information in parentheses is provided by the translator to clarify matters, which are obvious to insiders in the German passive fire protection market, but may be unclear or indeed misleading to outsiders. There are fundamental differences in the manner in which Germany approaches certification as well as approvals, compared to North America. It is noteworthy for the reader who is unfamiliar with this territory, to know the highlights of this process, as follows:

DIBt is an agency of the German federal government. In a way, DIBt is similar to a combination between ULC and SCC. DIBt writes standards, which are published in "communications" (=Mitteilungen), similar to the federal gazette, which publishes Canadian government laws, or the federal register, which publishes the proceedings of the US House of Representatives. DIBt also accredits testing laboratories, which are also government owned and operated, either by the federal or by their Provincial/State (Länder) governments. If a manufacturer desires to market a firestop or fireproofing product, he or she must run a test in a DIBt accredited laboratory. If he or she passes the test, the laboratory will automatically forward the results to the appropriate person at DIBt and thus apply for approval by DIBt. The basic system tests are actually run in accordance with DIN4102. DIBt differentiates between building materials (Baustoffe) and building components (Bauteile). If you pass a firestop test, that whole system is a building component. However, if part of that seal is intumescent, this then is classified as a building material. There are separate classifications of building materials, most notably in terms of combustibility and flame spread performance, all of which are determined by means of testing to DIN4102. Intumescence is seen as a characteristic utilised in building material classification. Building materials, whose function must be verified on a regular basis, are subject to a mandatory certification regime. Some building materials are exempted from this process, such as those which deemed A1 noncombustible per DIN4102, i.e. concrete, stone, etc. or "B3" easily ignitable as per DIN4102, such as polyurethane foam. Both of these extremes are common sense, really. If something is entirely inorganic and dead to begin with, why bother verifying the obvious at further expense? B3 on the other hand (easily ignitable) is not exactly a feather in anyone's cap to begin with. It is not a designation strived for by anyone, but something to avoid entirely. However, anything in between those two extremes, A1 and B3, including intumescents, contain a certain organic component, which is subject to deterioration under many influences. Thus, it stands to reason, that the use of such materials and the efficacy of such materials depends on the long-term performance and maintenance of its most basic properties. When such materials break down or are adversely affected by environmental influences, they can become the weak link in the chain that is the fire safety plan of an occupancy. Thus it is mandatory in the Federal Republic of Germany to engage in certification programs, which provide due diligence in terms of the efficacy of such materials beyond the one-time system test. DIBt will not issue an approval of any passive fire protection system, utilising such limited combustibility materials, without a separate building material approval. One partial exception to this concept is the procedure translated herein, as the material testing is included with the system testing, all in one document. Thus, separate material testing is not necessary. Generally, both the building material (Baustoff) approval and the system approval (Bauteil) (be it a fire door gasket, a firestop or any such similar passive fire protection item) depend on the maintenance of positive periodic certification test results by a DIBt accredited governmental laboratory. In North America, our accreditation bodies (SCC and ANSI) have no such identical authority. Another large difference is that in Germany, chemical formulations and mix designs are not disclosed to the laboratory (as we do in North America - formulas are always part of the follow-up procedures disclosed to UL, ULC, WH, OPL and FM). Instead, in Germany, these formulas are disclosed exclusively to DIBt. DIBt embodies the quintessential, qualities of the incorruptible Prussian civil servant. Unlike North America, where it is not entirely unheard of to see laboratory personnel, with access to manufacturer formulations and process standards, who then leave the laboratory to work for private vendors (not that any country has a law against this, including Germany), whose product offerings may be enriched by the experience of the newly hired engineer, such instances are actually unheard of, when it comes to DIBt. DIBt enjoys an unsurpassed  and unbroken trust. Hence German manufacturers are often reluctant to share formulations with North American laboratories (it is not their own government after all), which is expensive to avoid, when one desires to import products or manufacture locally under a certification program. Thus, German governmental certification programs, as administered by governmental laboratories, do involve factory audits. However, the procedures are limited to verification of physical characteristics of the building material (which indicate whether or not there may be a problem worthy of investigation). Typically, characteristics and simple physical tests are chosen, which have a direct impact on the performance of the product. Tolerances are set by DIBt, which form part of the DIBt material and/or system approval. For instance, DIBt approved spray applied fireproofing plasters are subject to bi-annual factory audits as well as laboratory bench-scale tests in the case of TU Braunschweig, a superb facility. If routine tests yield results, which fall outside of the DIBt tolerances, as set out in the approval text, such results are automatically submitted by the laboratory to DIBt, which then quickly cancels the approval. If a tendency is noticed in results, which shows a leaning towards one of the tolerance extremes, the laboratory will notify the manufacturer. DIBt approvals are always limited in duration and are re-considered (and re-invoiced) at the end of each approval duration period. By contrast, in North America, the laboratory, apart from FM, does not ever issue an approval for a system (Bauteil). The term approval is specific to an installed configuration in the field, which is bounded and which is acceptable to the AHJ. In other words, the local fire prevention officer or the local building inspector can approve plans or an installed fire door or closure etc. Whoever refers to an approval from ULC, ULI, WH or OPL, is mistaken. These laboratories cannot issue approvals. They issue listings, which are test results backed by a certification program. When a passive fire protection item is installed in the field, in a bounded fashion, this can then be approved by the AHJ (authority having jurisdiction). The exception is FM, which issues system approvals against insurance requirements, which have nothing to do with building code compliance. In Germany, however, approvals per se are required, just like listings are required in North America, for systems (Bauteile) and materials (Baustoffe) before they are even delivered to the jobsite. Both systems theoretically accomplish the same objectives. The German system achieves a greater level of assurance that confidentiality is maintained (which protects the interests of the manufacturer who desires that his or her products not become the technological basis for someone else's new products) and that the product will actually work. The North American system presumes that when the formula and the production standard are disclosed and monitored, that so long as I make the product identically to the one used in the system test, it will work for all time to come (as the environmental influences other than fire exposure, which can destroy products are simply excluded from the certain test regimes). However, this system may go awry, in the event of changes to raw materials, which may not be immediately apparent. There is also a gradient in the vigilance of follow-up test procedures from one lab to another in North America. Thus the North American user and the AHJ are bound by law to accept and presume that all is well, when in fact that may or may not be the case, particularly in complex organic products, such as intumescents, or endothermic products, except in the case of materials or systems, which are subject to testing, which includes environmental exposures, such as UL1709, which is a superb standard. Having said that, neither system is of course perfect. Insiders familiar with practices on both sides of the Atlantic can see where each could learn from the other, particularly if there were more flexibility in the basic legislative set-up concerning certification and field approvals.

One must, bear in mind, that a report from a DIBt accredited laboratory only forms the basis for an application for approval by DIBt. In fact, the bottom of the report contains a mandatory and cautionary statement, indicating that the sole purpose of the report is to provide data to supplement an application for approval by DIBt. Once this request is received by DIBt, there is still the matter of convincing the SVA expert committee (which meets several times per year in Berlin) that what was done is proper and worthy of the approval. The translator has seen one case, where field data was submitted to DIBt, in connection with a delamination issue of a spray applied fireproofing. DIBt almost immediately imposed further restrictions on the vendor's approval to account for what had been found in the field and did not revert the approval back to the original state until sufficient data had been produced to prove beyond the shadow of a doubt that the problem was inadequate surface preparation (oily substrate), preventing a proper bond, thus acquitting the product.


from the work of expert committees (SVA)

SVA "Fire Behaviour of Building Components"

Chairman: Minister Councillor Temme

Secretary: OBR Hoppe

The (expert committee) SVA "Fire Behaviour of Building Components" has established 'Approval Guidelines for Reactive Fire Protection Systems on Structural Steel Building Components" dated November 1997 in its meeting of 17. November 1997. These approval guidelines supersede the "Guidelines for Testing and Approval of Intumescent Fire Protection Coatings on on Structural Steel Building Components for Determination of F30 Fire-Resistance Classification according to DIN4102 - September 1977 Edition.

Reactive fire protection systems are coatings utilised in structural fire protection, which become are activated when exposed to elevated temperatures during a fire and develop an insulating effect. These fire protection systems, which typically consist of a primer, for corrosion protection, the reactive component and a protective outer coating, and are applied to structural steel building components in order to increase their fire-resistance. The reactive components of such fire protection systems may be an intumescent, a subliming (or endothermic) coating or a combination of such products. The fire protection system is always tested and evaluated as a whole.

An update of the previous guidelines had become necessary because it was no longer appropriate due to the development of such fire protection systems, which are now achieving greater fire-resistance ratings.

Furthermore, the environmental (weather) exposure test procedures, which are used to provide data enabling approvals for exterior applications, have been modified, because the previous test procedures for environmental (weather) exposures, which these fire protection systems are subjected to, were inadequate.

These approval guidelines now also include an identification procedure, which determine the typical identity characteristics of each system. From now on, this procedure shall be used for all tests, which are intended to be used in obtaining DIBt approval. For systems, which are already approved, the "fingerprint" procedure shall be required for the next approval extension. (All DIBt approvals carry a limited duration.)

In cases of doubt, the fingerprint data shall be consulted.

- H e r z o g -

(Mrs. Herzog is a DIBt employee.)

Official Part

Approval Guidelines for Reactive Fire Protection Systems on Structural Steel Building Components

November 1997 Edition

1

Applicability

2

Definitions and Explanations

3

Applications of Fire Protection Systems

4

Requirements

5

Fire Test Procedures for Structural Steel Building Components

6

Tests for Proof of Durability

7

Test Procedures for Proof of Durability

8

Test Report

Appendix 1

Determination of Applied Thicknesses, Minimum Number and Location of Thermocouples

Appendix 2

Test Plan for Tests to Prove Durability and Corrosion Protection

Appendix 3

Plan for Short-Term Tests of Reactive Coating Systems for Exterior Applications

Appendix 4

Table 1: Sample Selection (with and without load) F30 and F60

Appendix 5

Table 2: Sample Selection (with and without load) F90

Appendix 6

Table 3: Sample Selection (with and without load) F30 through F60

Appendix 7

Table 4: Sample Selection (with and without load) F30 through F90

Appendix 8a

Beam Sample Construction, Open Profile

Appendix 8b

Beam Section Sample Construction, Open Profile

Appendix 9a

Column Sample Construction, Open Profile

Appendix 9b

Column Section Sample Construction, Open Profile

Appendix 10a

Round Hollow Steel Column Sample Construction

Appendix 10b

Round Hollow Steel Column Section Sample Construction

1 Applicability

1.1 These approval guidelines apply to testing of reactive fire protection systems, which are utilised as coatings for structural steel building components in order to increase their fire-resistance ratings(1).

1.2  These approval guidelines do not apply to testing of intumescent fire retardants for timber, which is used to obtain a B1 building materials classification as per DIN4102 (In North America, we use the Steiner tunnel test for this, in order to obtain a flame spread rating). These approval guidelines also do not apply to testing of reactive building materials in structural fire protection other than for the application described under §1.1.

1.3 These approval guidelines contain provisions for fire test procedures on steel building components as well as test procedures for proof of the durability of the (reactive fire protection coating) products.

2 Definitions and Applications

2.1 Reactive fire protection systems are coatings utilised in structural fire protection, which become are activated when exposed to elevated temperatures during a fire and develop an insulating effect.

2.2 These fire protection systems typically consist of a primer, for corrosion protection and/or to enhance adhesion in the case of galvanised substrates, the reactive component and the required outer protective coating. The reactive components of such fire protection systems may be an intumescent, a subliming (or endothermic) coating or a combination of such products. The coatings utilised for these purposes may be applied in single or multiple layers.

2.3 The fire protection system shall always be tested and evaluated as a whole.

3 Application of the Fire Protection Systems

3.1 The reactive fire protection systems shall be categorised in accordance with the expected use and the environmental exposures, which result from their use in these target locations and applications. The environmental exposures expected for these categories of use result in a specific test regime for each application, in this approval guideline, the results of which shall form the basis of judgment for durability of the reactive fire protection systems in terms of eligibility for (DIBt) approval.

3.2 Fire Protection Systems for Interior Use

The reactive fire protection systems are applied inside of buildings, which includes their use in open halls (i.e. buildings, which are not permanently enclosed by a building envelope) as well as their use under overhangs from buildings or roofs, which extend beyond the exterior walls and thus protect the fire protection systems from immediate precipitation but not other weather effects. These applications are expected to be subjected to short-term exposures of wetness (i.e. due to temperatures' falling below the dew point) and potentially exposures to chemicals. They shall not be used in areas, which are subject to constant wetness or permanent relative humidity above 90% and/or strongly aggressive gases.

3.3 Fire Protection Systems for Exterior Use

Fire protection systems for exterior use are directly exposed to the weather, such as strong rainfall and ultraviolet radiation. They may at times be subject to short-term chemical exposures as well. They shall not be used in areas, which are subject to constant wetness or permanent relative humidity above 90% and/or strongly aggressive gases.

4 Requirements

4.1 The reactive fire protection systems shall provide fire-resistance ratings to structural steel building components, which are thus protected from fire for a certain duration, which enables a fire-resistance classification in accordance with DIN4102 Part 2(2).

This requirement shall be deemed as fulfilled once fire testing in accordance with DIN4102 Part 2(2) on coated structural steel building components as per §5 has led to positive results.

4.2 The reactive fire protection systems shall be possess long-term efficacy.

This requirement shall be deemed as fulfilled once testing of the behaviour of the fire protection systems under their respective environmental exposures (see §3) in accordance with §6.3 has led to positive results.

4.3 The reactive fire protection systems shall remain firmly bonded to their substrates and remain effective under smoldering fire conditions, which deviate from the standard time/temperature curve mandated under DIN4102 Part 2(2).

This requirement shall be deemed as fulfilled once testing of the insulation capabilities of the fire protection systems in accordance with §7.2.2 has led to positive results.

4.4 The reactive fire protection systems shall be configured such that an unquestionable corrosion protection of the coated structural steel building components can be guaranteed.

This requirement shall be deemed as fulfilled once testing of the corrosion protection capabilities of the fire protection systems in accordance with §7.4 has led to positive results.

5 Fire Test Procedures for Structural Steel Building Components

5.1 Sample Selection

5.1.1 General

All fire tests of the structural steel building components, which serve the purpose of judgment of the fire protection systems (for eligibility for DIBt approvals) shall be conducted on whole, complete and identical systems for each application and each product, consisting of the corrosion protection layer (primer), the reactive components and the outer protective layer.

In the event that more than one product can be used for the primer or the outer protective layer, additional tests shall be conducted in order to establish (DIBt approval) eligibility for each such component.

5.1.2 Building Component Types and Profile Types

Fire testing shall be conducted for each application category of the fire protection systems on the following:

-Structural Steel Beams

   -with open profiles

   -with closed profiles if classification is sought for them

-Structural Steel Columns

   -with open profiles

   -with closed profiles if classification is sought for them

Test results obtained from structural steel beams and columns shall be applicable to components of framework (Fachwerkstäbe) structures.

Minimum fire protection coating thicknesses derived from test results obtained from building components with closed profiles shall also be acceptable for use on open profile building components. Minimum fire protection coating thicknesses derived from test results obtained from steel beams with open profiles F < F90 shall also be acceptable for use on open profile steel columns.

Minimum fire protection coating thicknesses derived from test results obtained from hollow structural steel columns with closed profiles shall also be acceptable for use on cast iron columns with identical profile factors.

5.1.3 Types of Steel

Samples shall be constructed utilising steel types S235 or S355 (3).

5.2 Sample Construction

5.2.1 Application of the Corrosion Protection (Primer)

The applicant (at ULC the term would be 'Submittor'; at DIBt, this becomes "Applicant", as the manufacturer or sponsor of the test is in fact applying for a governmental approval) shall indicate to the (DIBt accredited) test laboratory which product (primer) will be used. The steel samples shall be freed from rust and the substrates shall be coated with the primer at a thickness, which will be used in practice. This corrosion protection agent shall be used uniformly for all system tests.

In the event that the coating system is intended to be used on galvanised structural steel building components, proof shall be provided that a positive bond to the substrate can be ensured, under fire conditions. Such proof shall be provided by means of short-term weather exposure testing on steel sheets sized 500mm x 500mm x 5mm with a zinc coating of 150µm. If an additional bonding agent is used in this application, it shall be considered part of the overall system.

5.2.2 Application of the Reactive Component

The applicant shall apply the reactive component of the coating system in a manner chosen by her or him (e.g. spraying, rolling spackling) in one or several layers in the required thickness (compare §5.3.2.1).

In the event that the reactive component is intended to be applied in ways other than that, which was chosen for the sample preparation, the efficacy of such alternate methods of product application shall be demonstrated to the (DIBt accredited) laboratory [to ensure the avoidance of run-off or sliding off (of the applied reactive product)] by means of coating vertically oriented steel sheets. The dry coating thickness achieved shall be recorded. In order to determine the temperature rise, a steel sheet, which has been coated via such an alternative method, shall be tested in accordance with §7.2.1.

5.2.3 Application of the Outer Protective Layer (Sealer Coat)

The applicant shall apply the outer protective layer (sealer coat), which is an integral part of the coating system, in a manner chosen by her or him (e.g. spraying, rolling, spackling) in one, or if necessary two layers in the required thickness. The thickness of the finished layer shall be equivalent to that, which has been proven to be required throughout testing for durability in accordance with §6, for the necessary protection of the reactive component.

5.2.4 Measurement of applied Quantities and Coating Thickness

The total system combined thickness shall be measured immediately prior to the fire test.

The thickness of the individual layers, which contribute to the total system thickness, i.e. the primer, the reactive coating and the sealer coat shall be determined, if possible, throughout the multi-stage application process.

For the determination of the coating thicknesses (4) (average thickness and standard deviations) as well as the applied volumes, the following shall be used:

5.2.4.1 Following the application of the primer, its average thickness shall be determined via measurements in at least 20 equally spaced locations (on the lower flange and the web) on the 3m area of beams and columns. For beam and column sections, the coating thickness shall be determined through measurements in a minimum of 6 locations.

5.2.4.2 For open profiles, which are exposed to fire on three sides, the coating thickness shall be determined in accordance with Figure 1 (see Appendix 1) by locating respectively 10 measuring points on the bottom of the upper flange, 20 measuring points in the middle of the web, 10 measuring points on the top of the lower flange and 20 measuring points on the bottom of the lower flange.

The beam measuring points shall be equally spaced and located respectively in the middle of the 3m area. They shall not be positioned directly on the thermocouple locations (see §5.3.3).

5.2.4.3 For open profiles, which are exposed to fire on four sides, the coating thickness shall be determined by locating respectively 10 measuring points in the middle of the web and in the quarter points of the upper and lower flanges in accordance with Figure 2 (see Appendix 1).

For hollow structural steel columns, which are exposed to fire on four sides, the coating thickness shall be determined by locating measuring points along the axis, spread over the height in accordance with Figure 2 (see Appendix 1).

The column measuring points shall be equally spaced and located respectively in the middle of the 3m area. They shall not be positioned directly on the thermocouple locations (see §5.3.3).

5.2.4.4 For beams, separate average coating thicknesses shall be determined for the bottom of the lower flange and for the web. Furthermore, the total average thickness of the coating for the entire steel profile shall be determined, provided that  measuring locations were positioned in accordance with Appendix 1.

For columns the average coating thickness shall be determined uniformly from results of all measuring locations.

5.2.4.5 For beam and column sections a reduced number shall be chosen in conformance with Appendix 1. The average coating thickness shall be determined uniformly from results of all measuring locations.

5.2.5 Drying of the Samples

The coated samples shall be stored in a closed room at a temperature of 20 ± 10°C in a relative humidity of 40 to 75% until a mass equilibrium has been achieved. If the mass is not monitored, the drying period shall be 28 days. At the time of the fire test, the coating system must be dry.

5.3 Fire Test Procedures

5.3.1 General

Fire test procedures on coated and loaded building components must conform to the standard DIN4102 Part 2 (2) except where deviations are mandated within this document, which shall supersede any conflicting provisions of DIN4102 Part 2 (2).

5.3.2 Sample Selection

5.3.2.1 For every reactive fire protection system fire testing shall be conducted on coated building components of each building component and profile type, for which the product is intended to be used in practice, in accordance with §5.1.2.

In order to determine the required minimum dry coating thicknesses of the reactive component for a profile area, which reaches a relative value of U/A = 300m`¹ (M/D = 26.2), and to enable a calculation method for determining coating thicknesses versus the various profile factors, it is necessary to fire test several different sizes of steel samples, with a minimum of two samples. Fire testing choices (in terms of number of burns and number of samples) are dictated by the desired coverage of thickness factors for the various profile factors. (Note: While it is permissible to test only one very small sample and one very big one, this may not result in the thickness economies a manufacturer requires in order to be competitive.) At minimum, fire testing of steel building components must bound the minimum and the maximum coating thicknesses.

The profile with the largest relative value U/A is determined by the applicant's desired range of applications. Preferably the tolerance of U/A = 300m`¹ (M/D = 26.2) should apply.

5.3.2.2 In order to provide evidence of the fire-resistance class F90 (=in order to obtain a 90 minute fire-resistance rating) on open profiles, a minimum of one fire test on two loaded steel beams of U/A = 291m`¹ (M/D = 27) (or the selected upper tolerance) and one fire test on two loaded steel beams of U/A = 77m`¹ (M/D = 102) as well as two unloaded beam sections of U/A = 291m`¹ (M/D = 27) and three unloaded column sections of U/A = 73m`¹ (M/D = 107.5), U/A = 152m`¹ (M/D = 51.6), U/A = 292m`¹ (M/D = 26.9) shall be conducted.

Additionally, one fire test shall be conducted on one loaded column of open profile with U/A = 89m`¹ (M/D = 88.2). Immediately following the fire exposure, a hose-stream test shall be conducted on the exposed sample in accordance with DIN4102 Part 2 (2), see Appendix 5.

In order to provide evidence of the fire-resistance class F90 (=in order to obtain a 90 minute fire-resistance rating) on closed (hollow) profiles, a minimum of two fire tests shall be conducted on loaded columns consisting of steel pipes of 139.7mm diameter x 3.6mm wall thickness (U/A = 285m`¹ (M/D = 27.5),

(According to German steel tables, this is a welded 5.5" outside diameter pipe, as per DIN2458 [2.81] with an ID of 132.7mm or 5.22" and 12.1kg/m. The closest North American version of this pipe is a 5.5" tube. In North America, pipe sizes are indicated in NPS [Nominal Pipe Size], the unit of measure for which is inches, although that is not given per se. NPS2 is a 2" pipe. But contrary to our German friends, what is meant there is the ID or inside diameter. The OD of an NPS2 or 2" pipe is 2 3/8" or 2.375" or 60.33mm. Tubes, on the other hand are referenced by their outside diameter in inches. Thus a 6" tube has an OD of 6" or 152.4mm, whereas a 6" pipe or NPS6 has an OD of 6 5/8" or 6.625" or 168.28mm. Therefore, a 6" tube should theoretically fit snugly into a 6" pipe.)

and 139.7mm diameter x 12.5mm wall thickness (U/A = 87m`¹ (M/D = 90.2),

(This too is a 5.5" diameter pipe. But German steel tables [available to the translator - Stahlbau Kalender 1992 from Deutscher Stahlbau-Verband] as per DIN2458 [2.81] -welded steel pipes- and DIN2448 [2.81] -seamless steel pipes- indicate a "normal" wall thickness of 3.6mm and 4mm).

as well as on 3 unloaded steel column sections,  [U/A = 87m`¹ (M/D = 90.2), U/A = 160m`¹ (M/D = 49.1), U/A = 285m`¹ (M/D = 27.5)] (see Appendix 5).

5.3.2.3 In order to provide evidence of the fire-resistance class F60 (=in order to obtain a 60 minute fire-resistance rating) on open profiles, a minimum of one fire test on two loaded steel beams of U/A = 291m`¹ (M/D = 27) as well as one unloaded steel beam section of U/A = 291m`¹ (M/D = 27) as well as three unloaded column sections of U/A = 73m`¹ (M/D = 107.5), U/A = 152m`¹ (M/D = 51.6), U/A = 292m`¹ (M/D = 26.9) shall be conducted.

In order to provide evidence of the fire-resistance class F60 (=in order to obtain a 60 minute fire-resistance rating) on closed (hollow) profiles, a minimum of one fire test shall be conducted on a loaded column consisting of a steel pipe of 139.7mm diameter x 3.6mm wall thickness (U/A = 285m`¹ (M/D = 27.5),

(According to German steel tables, this is a welded 5.5" outside diameter pipe, as per DIN2458 [2.81] with an ID of 132.7mm or 5.22" and 12.1kg/m. The closest North American version of this pipe is a 5.5" tube. In North America, pipe sizes are indicated in NPS [Nominal Pipe Size], the unit of measure for which is inches, although that is not given per se. NPS2 is a 2" pipe. But contrary to our German friends, what is meant there is the ID or inside diameter. The OD of an NPS2 or 2" pipe is 2 3/8" or 2.375" or 60.33mm. Tubes, on the other hand are referenced by their outside diameter in inches. Thus a 6" tube has an OD of 6" or 152.4mm, whereas a 6" pipe or NPS6 has an OD of 6 5/8" or 6.625" or 168.28mm. Therefore, a 6" tube should theoretically fit snugly into a 6" pipe.)

as well as on 3 unloaded steel column sections,  [U/A = 87m`¹ (M/D = 90.2), U/A = 160m`¹ (M/D = 49.1), U/A = 285m`¹ (M/D = 27.5)] (see Appendix 4).

5.3.2.4  In order to provide evidence of the fire-resistance class F30 (=in order to obtain a 30 minute fire-resistance rating) on open profiles, a minimum of one fire test on two loaded steel beams of U/A = 291m`¹ (M/D = 27) and one un-loaded steel beam section of U/A = 291m`¹ (M/D = 27) as well as three unloaded column sections of U/A = 73m`¹ (M/D = 107.5), U/A = 152m`¹ (M/D = 51.6), U/A = 292m`¹ (M/D = 26.9) shall be conducted.

In order to provide evidence of the fire-resistance class F30 (=in order to obtain a 30 minute fire-resistance rating) on closed (hollow) profiles, a minimum of one fire test shall be conducted on a loaded column consisting of a steel pipe of 139.7mm diameter x 3.6mm wall thickness (U/A = 285m`¹ (M/D = 27.5),

(According to German steel tables, this is a welded 5.5" outside diameter pipe, as per DIN2458 [2.81] with an ID of 132.7mm or 5.22" and 12.1kg/m. The closest North American version of this pipe is a 5.5" tube. In North America, pipe sizes are indicated in NPS [Nominal Pipe Size], the unit of measure for which is inches, although that is not given per se. NPS2 is a 2" pipe. But contrary to our German friends, what is meant there is the ID or inside diameter. The OD of an NPS2 or 2" pipe is 2 3/8" or 2.375" or 60.33mm. Tubes, on the other hand are referenced by their outside diameter in inches. Thus a 6" tube has an OD of 6" or 152.4mm, whereas a 6" pipe or NPS6 has an OD of 6 5/8" or 6.625" or 168.28mm. Therefore, a 6" tube should theoretically fit snugly into a 6" pipe.)

as well as on 3 unloaded steel column sections,  [U/A = 87m`¹ (M/D = 90.2), U/A = 160m`¹ (M/D = 49.1), U/A = 285m`¹ (M/D = 27.5)] (see Appendix 4).

5.3.2.5 For proof with the goal of bounding fire-resistance classes F30 through F60, fire testing shall be conducted in accordance with paragraphs 5.3.2.3 and 5.3.2.4 (see Appendix 6). The loaded hollow steel column (F30) may be dispensed with.

5.3.2.6 For proof with the goal of bounding fire-resistance classes F30 through F90 on open profiles, a minimum of three fire tests shall be conducted on two (each) loaded steel beams [U/A = 291m`¹ (M/D = 27), U/A = 153m`¹ (M/D = 51.3), U/A = 77m`¹ (M/D = 101.9)] as well as 3 un-loaded beam sections [U/A = 291m`¹ (M/D = 27), U/A = 153m`¹ (M/D = 51.3), U/A = 77m`¹ (M/D = 101.9)] and eight un-loaded column sections [each three times U/A = 73m`¹ (M/D = 107.5) and U/A = 152m`¹ (M/D = 51.6), and two each U/A = 292m`¹ (M/D = 27).

Additionally, one fire test shall be conducted on one loaded column of open profile with U/A = 89m`¹ (M/D = 88.2). Immediately following the fire exposure, a hose-stream test shall be conducted on the exposed sample in accordance with DIN4102 Part 2 (2).

In order to provide evidence of the fire-resistance class F60 (=in order to obtain a 60 minute fire-resistance rating) on open profiles, a minimum of one fire test on two loaded steel beams of U/A = 291m`¹ (M/D = 27) as well as one unloaded steel beam section of U/A = 291m`¹ (M/D = 27) as well as three unloaded column sections of U/A = 73m`¹ (M/D = 107.5), U/A = 152m`¹ (M/D = 51.6), U/A = 292m`¹ (M/D = 26.9) shall be conducted.

For proof with the goal of bounding fire-resistance classes F30 through F90 on closed profiles (=in order to obtain a 30 through 60 minute fire-resistance ratings) on closed (hollow) profiles, a minimum of three fire tests shall be conducted on loaded columns consisting of a steel pipes (2 Ø139.7mm diameter x 3.6mm wall thickness, U/A = 285m`¹ (M/D = 27.5), and Ø139.7mm diameter x 12.5mm wall thickness, U/A = 87m`¹ (M/D = 90.2)

(According to German steel tables, the thinner of the two is a welded 5.5" outside diameter pipe, as per DIN2458 [2.81] with an ID of 132.7mm or 5.22" and 12.1kg/m. The closest North American version of this pipe is a 5.5" tube. In North America, pipe sizes are indicated in NPS [Nominal Pipe Size], the unit of measure for which is inches, although that is not given per se. NPS2 is a 2" pipe. But contrary to our German friends, what is meant there is the ID or inside diameter. The OD of an NPS2 or 2" pipe is 2 3/8" or 2.375" or 60.33mm. Tubes, on the other hand are referenced by their outside diameter in inches. Thus a 6" tube has an OD of 6" or 152.4mm, whereas a 6" pipe or NPS6 has an OD of 6 5/8" or 6.625" or 168.28mm. Therefore, a 6" tube should theoretically fit snugly into a 6" pipe. The thicker of the two pipes also is a 5.5" diameter pipe. But German steel tables [available to the translator - Stahlbau Kalender 1992 from Deutscher Stahlbau-Verband] as per DIN2458 [2.81] -welded steel pipes- and DIN2448 [2.81] -seamless steel pipes- indicate a "normal" wall thickness of 3.6mm and 4mm)

as well as on 3 unloaded steel column sections,  [U/A = 87m`¹ (M/D = 90.2), U/A = 160m`¹ (M/D = 49.1), U/A = 285m`¹ (M/D = 27.5)] (see Appendix 7).

Immediately following the fire test, the loaded column with U/A = 87m`¹ (M/D = 90.2) shall be exposed to a hose-stream test in accordance with DIN4102 Part 2 (2) (see Appendix 7). This exposure may be dispensed with if the open profile column was hose-stream tested.

5.3.3 Number and Position of Thermocouples

The thermocouple locations both on columns and beams as well as column sections and beam sections shall be mounted in accordance with Appendix 8a/8b and 9a/9b.

5.3.4 Furnace Thermocouples

In order to measure the furnace temperature thermocouples shall be located in front of the samples. The thermocouple locations shall be positioned with a minimum 25cm clearance to the furnace walls as well as with a 10cm clearance to the samples. The location of the thermocouples shall be governed by CEN TC 127 N 1082, two thermocouples per beam and per column section and six thermocouples per pair of beams and per pair of columns.

5.3.5 Fire Test Duration

During fire testing of loaded building components (beams and columns) the load shall be removed from the samples once the maximum buckling speed has been achieved, latest upon reaching of the steel temperature of 500°C. Testing shall then be further continued (via exposure to ETK - see below) until the maximum steel temperature has been achieved on the profiles.

ETK - standard temperature/time curve

Standard German and/or ISO temperature/time curve

The un-loaded profile sections shall be tested simultaneously with the loaded building components inside the same furnace.

5.3.6 Hose-Stream Test

For fire tests of columns intended to achieve the F90 fire-resistance rating, a hose-stream test shall be conducted in accordance with DIN4102 Part 2 (2), §6.2.10. For this test, the sample with the lowest U/A value and the lowest applied coating thickness shall be chosen.

5.4 Conclusions and Evaluation of Test Results

The test results of the building component tests, together with the temperature measurements on the profile sections shall be evaluated such that the minimum required dry coating thicknesses of the reactive component shall be established for applications in practice (via DIBt approvals, once the DIBt accredited laboratory has submitted the results to DIBt and the SVA expert committee at DIBt has approved them for issuance of a DIBt approval), specifically indicating the permissible building component, the profile type, up to a maximum tolerance of the profile factor (except that for the F30 fire-resistance class the factor is mandated by law), preferably up to U/A = 300m`¹ ( Cdn. M/D = 26.2) and the thickness tolerances established for each via testing in accordance with this document.

For proof of fire-resistance durations in accordance with tables 1 through 4 (Appendices 4 through 7) the test results up to and including the lowest tolerance of U/A = 60`¹ ( Cdn.  = 130.8) shall apply.

Furthermore, the coating thickness ranges achieved for lower U/A values for lower profile factors shall be determined, preferably for values up to U/A = 160`¹ ( Cdn.  = 49.1) and U/A = 100`¹ ( Cdn.  = 78.5), provided that this results in differences  in the required dry coating thicknesses of at least 150µm between profile factor ranges.

5.5 Test Report

The (DIBt accredited) test laboratory shall prepare a test report about the tests conducted in accordance with §5.3, which contains a sample description, the sample construction process, the test results as well as an observation record detailing events during the test period.

Specifically, the following details shall be required report contents:

-about the sample construction

  -the types of profiles including their respective U/A factors

  -the types of steel used in the samples

  -the products used for each of the three coating components (corrosion protection,

    reactive component and exterior protective layer)

  -the number of layers of each component as well as their respective means of application

    (i.e. spraying, rolling/painting, spackling),

-and about the test results

  -the type and time of failure of each sample,

  -the time to reach a steel temperature of 500°C of each sample,

  -the minimum dry coating thickness of the reactive component 

    determined/recommended via evaluation of all results relative to

    the various U/A profile factor ranges -

  -the building material class (available combustibility ranges are

    DIN4102 A1, A2, B1, B2 and B3, see translator's preamble above)

    of the coating

  -as well as the fire-resistance classifications in accordance with

    DIN4102 Part 2 (2) of the coated steel building component.

Principally, the coated steel building component, when coated with the subject product(s), shall be designated with respect to fire-resistance classifications in terms of the F durations and A or B combustibility classifications (i.e. F....AB) in accordance with DIN4102 Part 1 (6), unless an A building materials class can be proven for the coating.

6  Tests for Proof of Durability

6.1 General

The reactive fire protection systems (or the coatings, respectively) shall be exposed to testing in accordance with exposures mandated under paragraphs 6.2 and 6.3 (for the minimum number of samples, see Appendix 2).

Certain tests may be dispensed with, if the fire protection system (or the coating, respectively) is deemed in the experience of the manufacturer and/or the (DIBt accredited) test laboratory not to possess the appropriately required characteristics (to pass the test) and/or its field of application is appropriately restricted (so that the product will not be used in areas where it may fail because the DIBt approval resulting from such testing will exclude its use in such areas).

In the event that fire protection systems (or coatings, respectively) are available and to be qualified in several forms, the extent of required testing may be subject to agreement with the (DIBt accredited) test laboratory.

In case these guidelines are intended to be deviated from because of certain special product characteristics, prior permission shall be obtained from the approval body (= DIBt).

6.2 Basic Tests

6.2.1 The insulation factor of the fire protection system - measured as temperature increase - shall be determined in accordance with § 7.2.1

6.2.2 The thermal behaviour of the fire protection system in response to a smoldering fire exposure shall be tested in accordance with §7.2.2.

6.3 Test of the Behaviour of the Fire Protection System under Environmental Influences

6.3.1 The fire protection systems shall be exposed to conditions mandated by §7.3.2 for interior applications and, respectively, to conditions mandated by §7.3.3 for exterior applications in order to determine the influence of each environment on the respective subject fire protection systems.

6.3.2 In the event that the fire protection systems are of such composition or targeted at a unique field of application, such that they may be subject to and susceptible to damage from environmental influences other than those, which are mandated by §6.3.1, further testing concerning such specific conditions and the determination of their effect upon the subject fire protection systems may be imposed.

6.4 Test for the Determination of the Influence upon the Corrosion Protection

The fire protection systems shall be subject to exposures in accordance with §7.4, in order to determine the effect of the reactive component upon the corrosion protection.

7 Test Procedures for Proof of Durability

7.1 Sample Preparation

For all tests in accordance with paragraphs 7.2 and 7.3 coatings of identical chemical formulation (per fire protection system being investigated) shall be used.

The construction of samples shall conform with the manufacturer's application procedures for each fire protection system. All samples shall be stored until mass equilibrium has been achieved in a 'normal climate' (as per DIN 50 014 23/50-2) (7) prior to testing in accordance with paragraphs 7.2.1 and 7.2.2, as well as before and after testing in accordance with paragraphs 7.3.2 and 7.3.3.

The coating thicknesses shall be measured directly preceding the testing on >/= 20 equally spaced locations.

7.2 Basic Test Procedures

7.2.1 In order to determine the temperature rise, 2 samples each shall be fire tested in a pilot scale furnace conforming to DIN4102 Part 8 (8) in accordance with the ETK standard temperature/time curve. The samples shall consist of steel sheets, which have been freed of rust [via blasting (sandblasting, not explosives) to a rust removal grade of Sa 2½ in accordance with DIN 55 928 Part 4 (9)]. The samples shall be sized 500mm x 500mm x 5mm and shall act as the carrier material for the fire protection system. These carrier sheets, forming part of the overall samples shall be be coated on one side with the complete fire protection system. The opposite side of the steel sheets shall be primed. Each coating component of the fire protection system shall be applied such that the dry thickness on the sample is identical to that which is intended to be used in practice.

In the event that the subject fire protection system is intended to be qualified for exterior applications, an additional 2 steel sheets sized 300mm x 200mm x 5mm shall be prepared.

During the fire test the samples shall be covered on the unexposed side with vermiculite boards (100mm total thickness, 475kg/m³ density, thermal transmission factor of 0.14 W/mK) (10).

The pilot scale fire tests shall be terminated when the temperature in the middle of the steel sheets, on the unexposed side exceeds the critical temperature (11). The time to reach this critical temperature shall be recorded. Furthermore, the bond of the foam (char), the foam structure and foam height shall be described.

In the case of differences in the total coating thickness of > 1000µm, testing shall be conducted on the minimum and maximum coating thickness. In the event of thickness variances </= 1000µm testing shall be conducted on the minimum coating thickness.

7.2.2 In order to investigate thermal behaviour, testing shall be conducted on 2 samples in accordance with §7.2.1, except with a smoldering fire exposure conforming to EN 1363-2 (12) (currently in draft stage) §6.

The time to reach the critical steel temperature shall be recorded (11).

7.3 Test Procedures of the Behaviour under Environmental Influences

7.3.1 Sample Construction

For these tests, samples of the fire protection system shall be constructed in accordance with §7.2.1.

7.3.2 Exposures for Fire Protection Systems for Interior Applications

7.3.2.1 Short-term Tests (accelerated exposures)

2 samples, respectively 4 samples (delta s > 1000µm), conforming to § 7.2.1 shall be oriented vertically and exposed to 21 uninterrupted cycles of 4 hours at -20°C followed by 4 hours at +20°C and 80% relative humidity followed by 16 hours at +40°C and 50% relative humidity.

Additionally, 2 samples conforming to §7.2.1 - but without the exterior protective sealer coat - may be exposed.

7.3.2.2 Long-term Tests (Long-term Weather Exposures)

A total of 6 samples conforming to §7.2.1 shall be stored in an unheated room, which is roofed and well ventilated - affording rain and UV protection. 2 samples each shall be stored for durations of 2 years, 5 years and 10 years in accordance with §7.3.4 and then tested.

Should the fire protection system be used without an outer protective layer (sealer coat) samples shall likewise be stored in preparation for the subsequent test without such exterior protective layers and shall be tested and evaluated in accordance with §7.3.4.

7.3.3 Exposures for Fire Protection Systems for Exterior Applications

7.3.3.1 Short-term Tests (accelerated exposures)

A minimum of 2 samples, respectively 4 samples (delta s > 1000µm), consisting of steel sheets of minimum size 300mm x 200mm x 5mm shall be coated in accordance with §7.2.1 oriented vertically and exposed to the following conditions:

4 week exposure in a 'Global-UV-Test Apparatus Type BAM manufactured by 'Weiß Umwelttechnik GmbH Company' of Reiskirchen, Germany, or similar, to conditions in accordance with DIN53384 (13), Method B:

1 cycle = 6 hours

             = 5 hours dry phase, 55°C test room temperature and

                1 hour rain exposure, 20°C test room temperature

This cycle shall be repeated 112 times without interruption. Following this, the samples shall be visually examined, which shall then be followed by 2 weeks of exposure in conformance with Appendix 3

Additionally, 2 samples - but without the exterior protective sealer coat - may be exposed.

7.3.3.2 Long-term Tests (Long-term Weather Exposure)

A total of six samples conforming to §7.2.1 shall be exposed to sun, rain and all other weather influences outside.

These samples shall be positioned such that they are angled 45° from the horizontal and that the coated surfaces face south. This exterior storage shall take place in location, which is subject to a middle-European climate (frost exposure).

Two samples each shall be stored, evaluated and tested following storage durations of, respectively, 2, 5 and 10 years.

In the event that the fire protection system is intended to be used without an exterior protective sealer coat, test samples shall be prepared and stored without such exterior layers and evaluated and tested in accordance with §7.3.4.

7.3.4 Evaluation and further Tests of exposed Samples

7.3.4.1 Samples exposed in accordance with paragraphs 7.3.2 through 7.3.3 shall be examined for changes (such as efflorescence, exudations, dissolving, changes of shape).

7.3.4.2 The insulation factor of the fire protection systems exposed in accordance with paragraphs 7.3.2 through 7.3.3  - measured as heat rise - shall be determined in conformance with §7.2.1.

7.4 Test for the Determination of the Influence upon the Corrosion Protection

The following shall be subject to 10 cycles of exposures in accordance with DIN50017 KFW (14):

-3 samples, consisting of steel sheets, which have been freed of rust [via blasting (sandblasting, not explosives) to a rust removal grade of Sa 2½ in accordance with DIN 55 928 Part 4 (9)]. The samples shall be sized 200mm x 100mm x 5mm and shall act as the carrier material for the fire protection system. These carrier sheets, forming part of the overall samples shall be primed with the corrosion protection material on all sides., and

-5 samples, which are coated on one side with the corrosion protection material and on the opposite side with the fire protection system.

7.5 Test Plan

7.5.1 Evidence shall be produced in accordance with paragraphs 6.2 through 6.4.

7.5.2 The required tests and their respective minimum number of samples are summarised in Appendix 2.

7.6 Evaluation of Test Results and Conclusions

7.6.1 Following exposures in accordance with §6.3.1, there must not be substantial changes in results of the basic tests, compared with results obtained from samples which have not been subjected to environmental exposures, in terms of the reaching of the critical steel temperature of 500°C (see §6.2.1).

7.6.2 During the investigation of the thermal behaviour under a smoldering fire exposure in accordance with §7.2.2, the critical temperature (11) must be reached within a period of time equivalent to that, which was required to reach this temperature when tested in accordance with §7.2.1. This time results from the comparison of the integral under the standard temperature/time curve with the smoldering fire curve.

7.6.3 During the investigation of the thermal behaviour in accordance with §7.2.2, observations of the coating system shall be described (for instance running off, sliding off, dripping)

7.6.4 For conclusions on the samples exposed in accordance with §7.4, it shall be determined and recorded whether any rust spots and/or other changes became evident.

8 Test Report

The (DIBt accredited) test laboratory shall issue a report concerning tests run in accordance with §7, which includes results of all tests, descriptions of the samples and the test set-up as well as observations made during and after all tests (in accordance with a standardised format).

Particularly determinations concerning temperature rise and investigations of thermal behaviour

-of the average value of the dry coating thickness and

-the age of the samples

as well as any deviations from the procedures outlined in this document shall be recorded.

(#) Footnotes

1

The detailed formula (mix design) of the reactive component of the fire protection system (e.g. the intumescent) and the basic mix design of the sealer coat shall be disclosed to the German Institute for Building Technology as part of the application for approval procedures. Furthermore, identity characteristics of the reactive fire protection system shall be determined in accordance with procedures disclosed to the German Institute for Building Technology.

2

DIN4102 Part 2: Fire Behaviour of Building Materials and Building Components; Building Components; Definitions; Requirements and Tests (September 1977 Edition)

3

DIN EN 10025: Hot Rolled Goods made of Non-Alloy Building Steel; Technical Delivery Conditions

4

Measurement of Coating Thicknesses according to DIN50981 - Tests of metallurgical Coatings; Thickness Measurement of non-ferromagnetic Coatings on ferromagnetic Substrates; Magnetic Methods -

5

For the calculation of U/A values of steel profiles, the provisions of DIN4102 Part 4 shall apply.

6

DIN4102 Part 1: Fire Behaviour of Building Materials and Building Components; Building Components; Definitions; Requirements and Tests

7

DIN 50 014: Climates and their technical Applications; Normal Climates

8

DIN4102 Part 1: Fire Behaviour of Building Materials and Building Components; Pilot Scale Furnace

9

DIN 55 928 Part 4: Corrosion Protection of Steel Buildings through Coatings and outer protective Layers; Substrate Preparation and Test

10

For instance, "Vermitecta" Boards are suitable. (Note: Check with The Vermiculite Association.)

11

In Germany, the critical steel temperature is deemed to be 500°C.

12

EN 1363 Part 2: Fire Tests of Building Components to determine Fire-Resistance Durations; alternative Fire Conditions and Suitability Tests under special Conditions

13

DIN 53 384: Tests on Plastic Materials; Artificial Weather Exposures or Radiation inside of Test Apparatus; Exposure to UV Radiation

14

DIN 50 017: Climates and their technical Application; Water Condensate Test Climates

Appendix 1: Determination of Applied Thicknesses, Minimum Number and Location of Thermocouples

Anlage 1

Appendix 2: Test Plan for Tests to Prove Durability and Corrosion Protection

Row

Test

Paragraph

Type of Test

Sample Quantity

Sample Size

1

Basic Tests

7.2.1

Temperature Rise during ETK

2 (4)

2 (4)

500 x 500 x 5[mm]

300 x 200 x 5[mm]

2

Basic Tests

7.2.2

Thermal Behaviour during Smoldering Fire Exposure

2

500 x 500 x 5[mm]

3

Behaviour during Environmental Influences

7.3.2.1

Short-term Interior Tests

2

500 x 500 x 5[mm]

4

Behaviour during Environmental Influences

7.3.2.2

Long-term Interior Tests

6

500 x 500 x 5[mm]

5

Behaviour during Environmental Influences

7.3.3.1

Short-term Exterior Tests (without Sealer Coat)

2 (4)

2

300 x 200 x 5[mm]

300 x 200 x 5[mm]

6

Behaviour during Environmental Influences

7.3.3.2

Long-term Exterior Tests

6

500 x 500 x 5[mm]

7

Behaviour during Environmental Influences

7.4

Corrosion Protection

Corrosion Protection/Fire Protection System

3

 

5

200 x 100 x 5[mm]

200 x 100 x 5[mm]

Appendix 3: Plan for Short-Term Tests of Reactive Coating Systems for Exterior Applications

Day of the Week

Time of Day

08:00 - 14:00 hours

Time of Day

14:00 - 20:00 hours

Time of Day

20:00 - 02:00 hours

Time of Day

02:00 - 08:00 hours

Monday

20°C

95% relative humidity

70°C

dry

30°C

95% relative humidity

70°C

dry

Tuesday

20°C

95% relative humidity

70°C

20% relative humidity

30°C

95% relative humidity

70°C

dry

Wednesday

20°C

95% relative humidity

30°C

40% relative humidity

60°C

95% relative humidity

30°C

40% relative humidity

Thursday

20°C

95% relative humidity

30°C

40% relative humidity

60°C

95% relative humidity

30°C

40% relative humidity

Friday

-20°C

dry

40°C

95% relative humidity

-20°C

dry

40°C

95% relative humidity

Saturday

-20°C

dry

40°C

95% relative humidity

-20°C

dry

40°C

95% relative humidity

Sunday

-20°C

dry

40°C

95% relative humidity

-20°C

dry

40°C

95% relative humidity

Time periods between individual cycles shall be 30 minutes.

Appendix 4: Table 1: Sample Selection (with and without load) F30 and F60

Proof in Accordance with DIN4102 Part 2

Approval Applicability

Row

Building Component

Profile

U/A-Value m`¹

Coating Thickness

Building Component

Profile

U/A-Value m`¹

F30

1a

3-sided fire exposure

Beam Pair, loaded

Section, un-loaded

4-sided fire exposure

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

 

 

IPE140

IPE140

 

 

HEM240

 

HEB180

 

IPE180

 

 

291

291

 

 

73

 

152

 

292

 

 

max. 30

max. 30

 

 

min. 30

 

average 30

 

max. 30

 

 

Beams, Columns and Framework Components

 

 

open

I

 

 

</=300

 

 

 

</=100

 

</=160

1b

4-sided fire exposure

Hollow Column, loaded

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

 

 

139.7 x 3.6

 

139.7 x 12.5

 

139.7 x 6.3

139.7 x 3.6

 

 

285

 

87

 

160

285

 

 

max. 30

 

min. 30

 

average 30

max. 30

 

 

Columns and Framework Components

 

 

as desired I and O

 

 

</=300

 

</=100

 

</=160

F60

2a

3-sided fire exposure

Beam Pair, loaded

Section, un-loaded

4-sided fire exposure

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

 

 

IPE140

IPE140

 

 

HEM240

 

HEB180

 

IPE180

 

 

291

291

 

 

73

 

152

 

292

 

 

max. 30

max. 30

 

 

min. 30

 

average 30

 

max. 30

 

 

Beams, Columns and Framework Components

 

 

open

I

 

 

</=300

 

 

 

</=100

 

</=160

2b

4-sided fire exposure

Hollow Column, loaded

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

 

 

139.7 x 3.6

 

139.7 x 12.5

 

139.7 x 6.3

139.7 x 3.6

 

 

285

 

87

 

160

285

 

 

max. 30

 

min. 30

 

average 30

max. 30

 

 

Columns and Framework Components

 

 

as desired I and O

 

 

</=300

 

</=100

 

</=160

Appendix 5: Table 2: Sample Selection (with and without load) F90

Proof in Accordance with DIN4102 Part 2

Approval Applicability

Row

Building Component

Profile

U/A-Value m`¹

Coating Thickness

Building Component

Profile

U/A-Value m`¹

F90

3a

3-sided fire exposure

Beam Pair, loaded

 

Beam Pair, loaded

Section, un-loaded

Section, un-loaded

4-sided fire exposure

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

 

 

IPE140

 

HEM220

 

IPE140

 

HEM240

 

 

HEM240

HEB180

 

IPE180

 

 

291

 

77

 

291

 

77

 

 

73

152

 

292

 

 

max. 90

 

min. 30

 

max. 90

 

min. 90

 

 

min. 90

average 90

 

max. 90

 

 

Beams *

 

Framework Components**

 

 

open

 

I

 

 

</=300

 

</=100

 

 

 

 

 

 

 

</=160

3b

4-sided fire exposure

Profile Column , loaded

 

 

HEM220

 

 

89

 

 

min. 90

 

 

Columns

 

 

open, I

 

Hose-Stream Test

3c

4-sided fire exposure

Hollow Column, loaded

Hollow Column, loaded

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

 

 

139.7 x 3.6

 

139.7 x 12.5

 

139.7 x 12.5

 

139.7 x 6.3

139.7 x 3.6

 

 

285

 

87

 

87

 

160

285

 

 

max. 90

 

min. 90

 

max. 90

 

average 90

max. 30

 

 

Columns and Framework Components

 

 

as desired I and O

 

 

</=300

Hose-Stream Test***

 

</=100

 

</=160

* This also applies to columns, when the hose-stream test was passed.

**When beams and columns with open profiles are tested, the coating thickness on the beam shall be the crucial one.

***If the hose-stream test was conducted according to row 3b (profile column), a further such hose-stream test on the hollow column is not required.

Appendix 6: Table 3: Sample Selection (with and without load) F30 through F60

Proof in Accordance with DIN4102 Part 2

Approval Applicability

Row

Building Component

Profile

U/A-Value m`¹

Coating Thickness

Building Component

Profile

U/A-Value m`¹

F30 through F60

4

1a, 1b* + 2a, 2b

* The loaded hollow column is not required.

Appendix 7: Table 4: Sample Selection (with and without load) F30 through F90

Proof in Accordance with DIN4102 Part 2

Approval Applicability

Row

Building Component

Profile

U/A-Value m`¹

Coating Thickness

Building Component

Profile

U/A-Value m`¹

F30 through F90

5a

3-sided fire exposure

Beam Pair, loaded

 

Beam Pair, loaded

Beam Pair, loaded

 

Section, un-loaded

Section, un-loaded

Section, un-loaded

 

4-sided fire exposure

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

 

 

IPE140

 

IPE400

 

HEM220

 

IPE140

 

IPE400

 

HEM220

 

 

 

HEM240

HEB180

 

IPE180

HEM240

 

HEB180

 

IPE180

HEM240

 

HEB180

 

 

291

 

153

 

77

 

291

 

153

 

77

 

 

 

73

152

 

292

73

 

152

 

292

73

 

152

 

 

max. 90

 

average 30

 

min. 90

 

max. 90

 

average 30

 

min. 90

 

 

 

min. 90

average 90

 

max. 90

min. 60

 

average 60

 

max. 60

min. 30

 

average 30

 

 

Beams, Columns * and Framework Components**

 

 

open

I

 

 

</=300

 

</=100

 

 

 

 

 

 

 

 

 

 

 

</=160

 

 

 

</=100

 

</=160

 

</=300

</=100

 

</=160

 

5b

4-sided fire exposure

Profile Column , loaded

 

 

HEM220

 

 

89

 

 

min. 90

 

 

Columns

 

 

open, I

 

Hose-Stream Test

5c

4-sided fire exposure

Hollow Column, loaded

Hollow Column, loaded

Hollow Column, loaded

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

Column Sn., un-loaded

 

 

139.7 x 3.6

 

139.7 x 3.6

 

139.7 x 12.5

 

139.7 x 12.5

 

139.7 x 6.3

139.7 x 3.6

 

139.7 x 12.5

 

139.7

 

 

285

 

285

 

87

 

87

 

160

285

 

87

 

285

 

 

max. 30

 

max. 90

 

min. 90

 

min. 90

 

average 60

max. 90

 

min. 30

 

max. 30

 

 

Columns and Framework Components

 

 

as desired I and O

 

 

 

</=300

Hose-Stream Test***

 

 

</=100

 

</=160

* This also applies to columns, when the hose-stream test was passed.

**When beams and columns with open profiles are tested, the coating thickness on the beam shall be the crucial one.

***If the hose-stream test was conducted according to row 5b (profile column), a further such hose-stream test on the hollow column is not required.

Appendix 8a: Beam Sample Construction, Open Profile

Appendix 8b: Beam Section Sample Construction, Open Profile

Anlage 8

Appendix 9a: Column Sample Construction, Open Profile

Appendix 9b: Column Section Sample Construction, Open Profile

Anlage 9

Appendix 10a: Round Hollow Steel Column Sample Construction

Appendix 10b: Round Hollow Steel Column Section Sample Construction

Achim Hering, 30. February 2001, Capreol, ON, Canada

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