Epoxy Intumescent PFP – How It Works
PDVSA 31July2013
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Agenda
• Epoxy Intumescent History
• Why do we need Fireproofing?
• Epoxy PFP – What is it? How does it work?
• Epoxy vs. Lightweight Cementitious
• Application
• Potential Project Savings
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Epoxy Based Materials; History–The Apollo Heritage
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Passive Fire Protection – Why do we need it?
PERSONNEL PROTECTION :
• To allow escape/evacuation of people
• To provide a safe area or shelter for personnel for a
pre-determined period of time
ASSET PROTECTION :
• Protect structure or unit as well as inventory
• Prevent escalation
• Separate the fire from other assets
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Hydrocarbon Fire
• Fuel source is hydrocarbon based – e.g oil ,
petrochemical
• Characterized by a rapid heat rise, with very turbulent
air flow.
• Temperatures in these fires typically exceed 1000°C
(1830°F) within 5 minutes of ignition.
• A particularly severe subset of this type of Fire is a Jet
Fire
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Critical Core Temperature
• Steel is not combustible – However, it will lose 50% of its
yield strength as temperatures approach 1100F degrees
• Fireproofing is required to limit the maximum temperature
of the steel during a fire to between 1000F (538C) and 1200F
(649C).
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Intumescent Coatings – What are they?
Intumescent Coating:
“A coating which reacts to heat by swelling in a
controlled manner to many times its original
thickness to produce a carbonaceous char, which
acts as an insulating layer to protect the steel
substrate.”
Source: Fire protection for structural steel in buildings
Published by: Association for Specialist Fire Protection (ASFP) in
conjunction with Fire Test Study Group (FTSG) and Steel
Construction Institute (SCI)
Web Link: [Link]
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Intumescent – Expansion of Char in Fire
• A high quality epoxy resin system is
used for its excellent robustness &
anti-corrosive properties.
• It is filled with active ingredients
which react (intumesce) and swell in
a fire (typically expanding 5 to 10
times in volume), producing a tough,
carbonaceous char insulating layer.
• This char formation restricts the rate
of temperature increase of the steel
& prolongs its load bearing capacity
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Physical Properties
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Intumescent – Early Stages of Fire
Fire
Fire
Duration
Design
Duration
Char
Reaction Zone
Unreacted Material
Substrate
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Intumescent – Middle Stages of Fire
Fire
Fire
Duration
Design
Duration
Char
Reaction Zone
Unreacted Material
Substrate
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Intumescent – Late Stages of Fire
Fire
Fire
Duration
Design
Duration
Char
Reaction Zone
Unreacted Material
Substrate
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Passive Fire Protection Overview
•At around 180 to
200’c the coating
starts to react
•As the fire
intensifies the
“Swelling” reaction
starts to take place
•The reaction will not
be instant this will
swell during the fire
duration
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Post Fire - Char Formation
Epoxy Char
• Early reaction to give high initial insulation
• 5-10 times expansion ratio
• Produces a hard, inflexible char
• Excellent for jet fire
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Before & After Fire Exposure
Photo of I-beam coated with an epoxy intumescent material before & after fire
exposure showing expansion of char
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
ANSI / UL 1709 – Fire Test
The ANSI/UL1709 fire test standard
Widely recognised standard for PFP in the
onshore oil, gas and petrochemical worldwide
market
High heat rise curve
Hydrocarbon fires
Test Requirements
Time to 538°C (1000°F) average T/C
or 600°C peak T/C
Tested at Underwriters Laboratories, Chicago,
USA
Fire ratings - ½ to 3½ hours
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Cementitious Fireproofing:
The Established Standard
• Portland cement based product.
• Primarily an Insulative Material.
• Contains expanded aggregates such as vermiculate and pearlite
along with other lightweight mineral fillers.
• Achieves reduced density and poor thermal conductivity.
• Absorbs Heat and Flame Retardant.
• Magnesium oxychloride, calcium aluminate, and calcium
phosphate react, absorbing energy and emitting flame retardant
gases.
• Dissipates heat
• Retained water evaporates, carrying energy away from the steel.
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Epoxy Intumescent Fireproofing:
The New(er) Alternative.
• Definition – Intumescent Coating:
“A coating which reacts to heat by swelling in a controlled manner
to many times its original thickness to produce a carbonaceous
char, which acts as an insulating layer to protect the steel
substrate.”
• Starch or Pentaerythritol act as a carbon source, along with phosphate
as a catalyst, react to form a carbonaceous char.
• Melamine or chlorinated paraffin act as a blowing agent, expanding the
char between 5 and 10 times its original volume.
• Epoxy resin as the binder along with carbon fiber mesh holds the
expanded char together.
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Reinforcement Requirements
Cementitious Epoxy Intumescent
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Comparison of Block-Out Requirements
for Structural Connections
Cementitious Epoxy Intumescent
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Shipping: How Much Steel per
Truckload.
Cementitious Epoxy Intumescent
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Damage and Repairs
• Damage for cementitious projects is
found to be up to 30%
• Damage occurs from flexing during lifts
and mechanical damage from
installation and associated
construction activities.
Epoxy Intumescent
<1% Repair
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Cementitious vs. Epoxy Intumescent
Cementitious Process Epoxy Process
Galvanize the Sandblast &
steel Prime Steel
One Contractor can
Blast, Prime, and
Ship Galvanized
Apply Chartek; then
steel to applicator
ship within 48 hours
Apply Epoxy
7 – 28 days to Material in
cure before Apply Cementitious shop
Material in shop
Shipping
Total Weight Total Weight
4+ Pounds per Sq. Foot 2 Pounds per Sq. Foot Ship to
Ship to Location
Location
60% Difference
Associated Cost Associated Cost Field
Field Application •Block Out Area still •Block Out Area still Application
to be complete 20% to be complete 5%
•Up to 30 % Damage •Less Than1% Damage
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Level of Fireproofing Completed
in Shop
Cementitious Epoxy Intumescent
80% Complete 95% Complete
In the Shop
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Weathering & Corrosion
Resistance of Epoxy Intumescent
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Shop Application = Productivity
Cementitious PFP Epoxy PFP
7-28 days curing prior to Epoxy cures in less than
shipping 24 hours
More rigging required; Less rigging required; less
more weight weight
80% complete at the 95% complete at the
shop; larger “block-outs” shop; smaller “block-outs”
Tedious preparation that User friendly application
slows application process for increased productivity
Must be topcoated Not topcoat dependant
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Steel in - Steel out!
24-48 hours
Timeframe that Epoxy Intumescent is fully
cured and damage resistant. Unlike
cementitious fire protection it can be top coated
within a similar timeframe.
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Cementitious Based Materials
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Cementitious Based Materials
• Materials are held in place
by reinforcing
• The steel is usually boxed or
shuttered with installation of
a reinforcement mesh
supported by welded studs
in the middle section of the
coating
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Epoxy Intumescent vs. Cemetitious
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Reinforcement Methods
Metal mesh and pins
Welded pins not required
Metal mesh not required
No hot work on site
Cementitious Cementitious Epoxy Intumescent
Pins attached to the Mesh held in place Epoxy applied through &
substrate by the pins over the mesh
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Reinforcement Methods
Epoxy Mesh System
Easily installed
No pins required
Rolled into mid-film
Carbon fibre composite Typical Epoxy Mesh
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
The Potential Application Savings
Potential direct application savings using Epoxy materials are:
Reduced Material Cost
Lower film thickness = Less material
Lower density = Less material
Reduced mesh requirements = Less material
Reduced Application Costs
Lower film thickness = Faster application
Reduced mesh requirements = Faster application
Faster cure = Increased productivity
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
The Potential Transport Savings
Lower Weight:
Typically 40 to 60% less than “Lightweight” cementitious
Typically 80% less than concrete
Lower Volume
Less wagon loads – typically ½ to ⅓ the number required
No more – 1 truck in, 3 trucks out!
Reduced Damaged
Robust epoxy resin - damage resistant
Able to sling using fabric straps
Will not crack or disbond
Suitable for use at ground level – unlike “lightweight” cementitious
materials.
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
The Potential Site Cost Savings
Reduced Tie-in Connections / Field Joints:
Faster application = less manhours
Reduced scaffold time
Reduced weather down time & protection costs
Reduced mesh requirements = Less material
Reduced site activity = Improved safety !
Reduced Steel Erection Costs and Damage
Robust Epoxy Resin = little or no transport / handling damage
Lighter / Less Bulky = Easier handling
Not prone to damage from other trades working on site
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Reduced Life Cycle Cost
Maintenance Free:
No ongoing crack repairs
Eliminates corrosion under PFP – not topcoat dependent
Reduced scaffold costs
Reduced activities on live plant = Improved Safety !
Reduced Topcoat Repair
Not topcoat dependent
Long life – good aesthetics
Not prone to damage from other trades working on site
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Spray Application Equipment
Plural spray application
• Fast
• Low waste
• Solvent free
• No pot life restriction
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Application of Epoxy
Plural spray projects
Work being carried out is on a
major offshore new build where
the contractor utilized the
“Plural twin component
machine”
Run clip
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Application of Epoxy
Hand application
In many instances due to uncompleted design or
simply new steelwork required, very often these
small “Tie In” areas are performed by Hand
Application.
The procedures for mixing and application are
detailed in the Application Manual
Simple hand tools
used to apply Chartek
by hand
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Application of Epoxy
Modified Single leg Application
For medium sized areas proficient applicators can use the
Modified single leg machines.
It must be noted using this method you are running curing
material through the pump
Planning is essential using this method
General
equipment
Modified single
leg pump
Static mixing
machine
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Epoxy v Cement Based Comparison
Area Criteria Concrete "Lightweight" Chartek 1709 Epoxy
Vermiculite Epoxy Advantage
Cement Intumescent
Weight 2500 kg/m³ 800 kg/m³ 1000 kg/m³ n/a
Installed Weight (Low) 63 kg/m² 16 kg/m² 5 kg/m² Yes
Weight
Installed Weight (Typical) 75 kg/m² 24 kg/m² 8 kg/m² Yes
Installed Weight (High) 125 kg/m² 32 kg/m² 15 kg/m² Yes
Ease Of Installation Poor Good Good Equal
Stud Welding Required Some Yes No Yes
Reinforcement Method Very Complex Complex Simple Yes
Application Curing Time 10 to 21 days 5 to 10 Days 24 Hours Yes
Speed of Application Slow Medium Fast Yes
Block out Distance 450 mm 450 mm 200 mm Yes
Applicability to all substrates Poor Good Very Good Yes
Porosity Good Poor Excellent Yes
Weathering
Dependent on topcoat No Yes No Yes
& Corrosion
Corrosion Protection Medium Medium High Yes
Resistance to Impact Damage Good Poor Excellent Yes
Bond Strength Medium Low Very High Yes
Strength Expansion & Contraction with steel Poor Poor Good Yes
Suitable for use at ground level Yes No Yes Yes
Resisatnce to abrasion Good Poor Very Good Yes
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
Epoxy v Cement Based Comparison
Area Criteria Concrete "Lightweight" Chartek 1709 Epoxy
Vermiculite Epoxy Advantage
Cement Intumescent
Max Operating Substrate Temp Unknown 50 °C 80 °C Yes
Temperture Min Operating Substrate Temp Unknown 1 °C -30 °C Yes
Resistance Freeze / Thaw Damage Unknown Yes No Yes
Cryogenic Spill Resistance Unknown 10 mins (if dry) 1 Hour Yes
UL Rated No Yes Yes Equal
Fire Jet Fire Resistant Explosive Spalling Yes Yes Equal
Resistance Explosion Resistance Unknown Good Very Good Yes
Hose Stream Resistance Unknown Good Good Equal
Flexible in Transport & Operation Poor Poor Good Yes
Shipping &
Increased Volume & Weight High Medium Low Yes
Transport
Suseptable to Cracking Unknown Poor Good Yes
Initial Installed Cost Low Medium High No
Life before 1st Maintenance/Top Coat 10 Years 5 - 10 Years 20 Years Yes
Total Life Cycle Cost Medium Medium - High Low Yes
Cost
Remove &
Remove & Replace Minimal Touch-
Maintenance Activity Replace / Seal / Yes
/ Seal up of Top Coat
Top Coat
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings