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Engineering Stability Since 1881                                                              February 2012

Testing Requirements for Sprayed Fire Resistive Materials Thickness

SFRM This article discusses testing requirements for thickness of Sprayed Fire-Resistive Materials (SFRM) as specified in the International Building Code, Chapter 17. Requirements for SFRM thickness testing that are common to both the 2006 and 2009 IBC Codes are outlined below. The modifications to 2006 introduced by IBC 2009 will be clarified in a subsequent article.

SFRM are applied to steel frame structures to achieve the minimum required fire rating for the particular construction. IBC chapter 17, (section 1704.10 in the IBC 2006, and section 1704.12 in the IBC 2009) specifies the corresponding testing methodologies and minimum required testing frequencies to test compliance of SFRM to the design.

According to IBC, SFRM testing addresses three characteristics of the in-place material and prescribes three respective testing methodologies to evaluate it. The applied SFRM thickness, bond strength, and density must all be tested. The Code requires that the testing methodology for both thickness and bond strength conform to ASTM E605, and that testing for density adhere to ASTM E736.

SFRM must be applied to a minimum average thickness as prescribed in the approved contract documents. Typically, an Underwriters Laboratories (UL) design is denoted on the drawings corresponding to the required minimum fire rating for the steel frame assembly. Thickness requirements are specified in the UL design specific to particular, commercially available SFRM products. The ‘06 and ‘09 Codes require that tests be conducted on a minimum of 25 percent of structural members on each floor.

With respect to sprayed decking, one test must be conducted per 1,000 square feet of floor area. It should be noted that the testing frequency specified in IBC ‘06/’09 is stricter than the ASTM standard (E605), which only requires one test on each type of element (including decking) per 10,000 square feet of floor area. Inspection of code-compliant construction must, obviously, adhere to the stricter IBC standard.

One thickness test comprises a set of individual measurements, the number of which depends on the type of element. For example, one test on a sprayed deck consists of a minimum of four separate thickness measurements. For a wide flange column, twelve locations are specified on the perimeter of the column (in plan view), and two sets of twelve measurements are to be taken 12 inches apart along the column.

One test (i.e., one set of measurements on a given element or deck area) is evaluated for pass/fail with respect to two criteria, both of which must be met in order to achieve a passing result:

  • The average of the set of thickness measurements must meet or exceed the design thickness, and
  • Each individual measurement must meet or exceed an allowable minimum. The minimum allowable individual thickness is computed as the maximum of two computations: the design thickness times 0.75, and the design thickness minus 0.25 inches.

In practice, this means that the average SFRM thickness on a member might meet or even exceed the design thickness, but the member could still fail due to one failing individual measurement. This fact is, sometimes, the cause of frustration and misunderstanding on the part of the fireproofing contractor. It may be their view that a large quantity of SFRM has been applied to the element but the inspector, nevertheless, fails it due to one deficient individual measurement. This can come across as nitpicking if the Code is not clearly explained and understood, and inspectors are encouraged to be both conversant in the Code and patient but firm in explaining failing test results to contractors.

This article was written by Gary Pasquarell, Ph.D., P.E., Manager, CMT Services in our Roanoke office. Please feel free to contact Gary if you have any questions.

The Ranks of F&R's Professional Engineers Continues to Grow!

F&R is proud to announce that four of our staff engineers have passed the PE exam. Please join us in congratulating the following dedicated F&R professionals.

David Gibbs David Gibbs, P.E. has been with F&R's Fredericklsburg office for four years. He is responsible for project management, development of subsurface exploration programs, coordinating and supervising field activities, engineering calculations and soils analyses required to develop geotechnical recommendations, and the preparation of geotechnical reports providing foundation, pavement, retaining wall, and slope recommendations for various projects. He has gained experience with shallow and deep foundation design, lateral earth pressure evaluations, soil improvement analysis, soil slope stability analysis, and failure analysis.

Nate Schwarz Nate Schwarz, P.E. has been serving in F&R's Richmond office for four years. He is responsible for conducting various construction assessments including footing subgrade, reinforcing steel, concrete, masonry, and fill placement inspections. He regularly uses ground penetrating radar as a means to locate steel and conduit in existing structures due for reconstruction.

 

 

Ben Whitley Benjamin Whitley, P.E. has been with F&R since 2005 and has extensive experience providing clients in our Raleigh office with both environmental and materials testing/special inspection services. Ben Whitley’s duties include preparation of technical reports, as well as performing environmental investigative studies, Phase I Environmental Site Assessments (ESAs) and Environmental Screenings. Prior to joining F&R’s Environmental Services Department, Mr. Whitley had the opportunity to work for F&R’s Construction Materials Department, where he provided project management services on a wide variety of projects.

 

Jeff Yoder Jeffery Yoder, P.E. has served as a staff professional in our Charlotte office since 2000 and has over ten years of experience in providing construction materials testing and geotechnical engineering services. Mr. Yoder is responsible for managing the field and laboratory testing programs for commercial construction projects. His duties include proofrolling subgrade, test pit and undercut observation, footing inspection, reinforcing steel inspection, structural masonry inspection, field technician management and report preparation. He has extensive experience in managing projects requiring Special Inspections by Chapter 17 of the North Carolina State Building Code.

Mark Terrell Rejoins F&R as Engineering Manager

Mark Terrell

F&R is pleased to announce that Mark Terrell, PE has rejoined F&R as the Engineering Manager for our Charlotte, North Carolina office. He is a professional engineer practicing Lean Six Sigma methods with extensive experience in materials and laboratory testing as well as geotechnical engineering. In his new position, Mr. Terrell will be responsible for providing the leadership needed to ensure that all of F&R Charlotte's clients receive the high quality engineering support they deserve.

Mr. Terrell has more than 20 years of experience working with shallow and deep foundation design; Pile Driving Analyzer (PDA); post-tension cable structures; North Carolina and Florida Department of Transportation projects; surcharge design and monitoring; Interstate highway bridge construction, design, testing, and inspection; landfill construction inspection; earthen dam and levee design and permitting; stormwater, surfacewater and groundwater modeling; and extensive laboratory testing for a broad spectrum or ASTM, AASHTO, CMEC, and USACE test methods. His Lean Six Sigma knowledge includes Cause and Effect analysis, Failure Mode and Effects Analysis (FMAE), Pareto Analysis, process mapping and capability analysis, and statistical modeling.

In 2008 and 2009 as a seconded employee at Bechtel Power in Frederick, MD, he performed geotechnical design analysis for the USEPR nuclear power plant at Calvert Cliff, MD in accordance with NRC NQA1 requirements. On a 14-month assignment in 2009 and 2010, he provided geotechnical basis of design engineering for the State of California and USACE on the 40-mile long Sacramento Levee project including seepage and stability analysis, seismic, liquefaction and lateral spread modeling, and pumping plant and canal design.

Prior to rejoining F&R, Mr. Terrell served as a Senior Professional Engineer in the Charlotte office of Kleinfelder.

Christopher Hahn to Lead Chesapeake Environmental

Christopher Hahn

Christopher Hahn, REM has joined F&R as the leader of the Environmental Department for our Chesapeake, Virginia office. With nearly 20 years of environmental project experience, Christopher will be responsible for providing the leadership needed to ensure that all of F&R Chesapeake’s environmental clients receive the high quality support they deserve.

Mr. Hahn has over nineteen years of experience in the environmental consulting field, and is familiar with HUD, EPA, and OSHA as well as local and state regulations and guidelines. Mr. Hahn has an extensive background in environmental site assessments, site characterization studies and remediation design for projects ranging from residential development to large-scale industrial complexes.

Mr. Hahn also has decades of technical and field experience in the area of industrial hygiene and has been involved in all phases of asbestos projects including inspection, abatement design, project monitoring, hazard assessment, cost estimation, report preparation, and specifications. He also has broad experience in lead containing paint investigation, risk assessments, and related activities. Additionally, Mr. Hahn is knowledgeable in emissions testing for industrial/manufacturing facilities, indoor air quality projects, worker safety compliance and inspection, noise level surveys, and hazardous materials sampling.

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