Text

Engineering Design Info,Thermo-Lag 330-1 Subliming Coating Envelope Sys for Fine Resistive Enhancement of Critical Components of Nuclear Power Generating Facilities, Vol 2
	ML17139A456
Person / Time
Site:	Susquehanna
Issue date:	08/31/1981
From:	; TSI, INC.
To:	;
Shared Package
ML17139A454	List: ML17139A453; ML17139A455; ML17139A456; ML18026A232;
References
	90181, 90181-V02, 90181-V2, NUDOCS 8111040244
	Download: ML17139A456 (337)
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TSI TECHNICAL NOTE 90181 ENGINEERING DESIGN INFORMATION THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM FOR FIRE RESISTIVE ENHANCEMENT OF CRITICAL COMPONENTS OF NUCLEAR POWER GENERATING FACILITIES Siif040244 8ii026 PDR ADQCK 05000387 VOLUME TWO F PDR LL u '<< -au -l u I I al.',J AUGUST 1981 RECORDS FACILITYBRANCH THE ATTACHED FILES ARE OFFICIAL RECORDS OF THE DIVISION OF DOCUMENT CONTROL. THEY HAVE BEEN CHARGED TO YOU FOR A LIMITED TIME PERIOD AND MUST BE RETURNED TO THE RECORDS FACILITY Scar".-.~ 5- 387 BRANCH 016. PLEASE DO NOT SEND DOCUMENTS C-;.',; I; Stt too-oZ.&S CHARGED OUT THROUGH THE MAIL. REMOVAL OF ANY 6,,"~

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<<<<gg-', III II gg PAGE(S) FROM DOCUMENT FOR REPRODUCTION MUST B 4 H64w, '<<~

BE REFERRED TO FILE PERSONNEL. INC.

3260 BRANNON AVE. ~ ST. LOUIS, MISSOURI 63138

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TABLE OF CONTENTS VOLUME I SECTION TITLE ABSTRACT THERMO-LAG GENERAL METHOD OF OPERATION TSI TECHNICAL NOTE 71880 PART 1 -THERMO-LAG 330 SUBLIMING COATING LISTING OF SELECTED APPROVALS FROM INDEPENDENT TESTING AND UNDERWRITING AGENCIES PART 2 REFERENCE LIST OF SELECTED USERS OF THERMO-LAG SUBLIMING COMPOUNDS PHOTOGRAPHS OF THERMO-LAG 330-1 SUBLIMING COATING INSTALLATIONS DATA SHEETS FOR:

THERMO-LAG 330-1 SUBLIMING COATING THERMO-LAG 350 TWO PART SPILL RESISTANCE TOPCOAT THERMO-LAG STRESS SKIN TYPE 330-69 THERMO-LAG 330-70 CONFORMABLE CERAMIC BLANKET THERMO-LAG FIBERGLASS ARMORING

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TABLE OF CONTENTS (CONTINUED)

VOLUME I SECTION TITLE ENGINEERING REPORT ON ONE HOUR ASTM E119 FIRE SIMULATION FACILITY FIRE TEST FOLLOWED BY A SHORT TERM WATER HOSE STREAM IMPACT TEST ON A NUCLEAR FACILITY CLASS 1E CABLE TRAY, CONDUITS AND AIR DROP ASSEMBLY FIRE ENDURANCE TESTS ON CABLE TRAYS, CONDUITS AND CABLE DROP ASSEMBLIES PROTECTED WITH THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM ENGINEERING REPORT ON ONE HOUR ASTM E119 FIRE SIMULATION FACILITY FIRE TEST FOLLOWED BY A SHORT TERM WATER HOSE STREAM IMPACT TEST ON A NUCLEAR FACILITY CLASS 1E CABLE CONDUIT ASSEMBLY UNDERWRITERS LABORATORIES REPORT NOS. R6076 SURFACE BURNING CHARACTERISTICS OF GENERAL PURPOSE COATINGS A. THERMO-LAG 330-1 SUBLIMING COATING B. THERMO-LAG 350 TWO PART SPILL RESISTANT TOPCOAT 10 TSI TECHNICAL NOTE 10280 EVALUATION OF THE WEATHERING CHARACTERISTICS OF THERMO-LAG 330-1 SUBLIMING COMPOUND AS APPLIED TO METAL SUBSTRATES

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TABLE OF CONTENTS (CONTINUED)

VOLUME II SECTION TITLE THREE HOUR TESTS ON THERMO-LAG 330 UNDERWRITERS LABORATORIES DESIGN'NO. X611 MONSANTO SPECIAL REPORT 8008 FACTORY MUTUAL REPORT NUMBER 23187 FACTORY MUTUAL REPORT NUMBER'23187.1 12 UNDERWRITERS LABORATORIES FILE NO. 6802-7 REPORT ON THE PERFORMANCE OF A STEEL LOAD BEARING WALL ASSEMBLY PROTECTED WITH A'MASTIC COATING DURING'FIRE AND HOSE STREAM TESTS 13 UNDERWRITERS LABORATORIES FILE NO. R6802 FIVE HOUR FIRE TESTS PER ASTM E119 THREE HOUR FIRE ENDURANCE TESTS ON TSI'S CONFORMABLE THERMO-LAG 330 STRESS SKIN FIRE WALL ASSEMBLY 15 FACTORY MUTUAL REPORT NO. 23160.1 TWO HOURS FIRE ENDURANCE TEST 16 INTERIM MEMORADUM REPORT NO. 459 COMPARISON OF VARIOUS THER'YSTEMS FOR THE PROTECTION OF RAIL TANK CARS TESTED AT THE FRA/BRL TORCHING FACILITY

TABLE OF CONTENTS (CONTINUED)

VOLUME II SECTION TITLE TSI TECHNICAL NOTE 77629 THERMO-LAG'30 SUBLIMING COATING SYSTEM SELECTED DATA ON WATER IMPINGEMENT,TESTS, FULL SCALE TORCH TESTS AND FIRE ENGULFMENT TESTS 18 PRELIMINARY ACCIDENT REPORT TANK CAR DERAILMENT JOAQUIN; TEXAS 19 TSI TECHNICAL NOTE 80181 THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM APPLICATION PROCEDURES 20 OUTLINE OF TSI'S QUALITY ASSURANCE AND QUALITY CONTROL SYSTEM

UXDERM'RITERS LABORATORIES l.iC.

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3260 Brannon Ave.

St; Louis, liO 63139 Atten tion: R. Fe 1 dman

Subject:

MASTIC COATINGS (CDWZ)

Gentlemen:

We are enclosing one copy of the Report revision covering-the above subject. The revision consists of the folloving:

Revised illustration 6 for report issued 6-5-78, dated 1-S-79.

Very truly yours, G. D. Palikij Fire Protection Dept.

GP-.r g encl.

Novctnbcr 3, 1978 Guide BXUV. t)tS11-A card.)

Ftro )tcalatanco Ratings. Design No. X6ll Rotint) 3 Hr.

(Continued on Xstl-8 card.)

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rwritcrs Laboratories Inc.

This card is issued by Un

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TIME, MINUTES ILL.6 R 6802-6A

an independent, nu.'-fur-prufi t organi "atun testi ny J'or puolic safety File R6802-6A Project 77NK422 June 5 1978 REPORT on MASTIC COATING APPLIED TO A M14X228 STEEL COLUMN YSI, Inc.

St. Louis, Missouri Copyright C 1978 Underwriters Laborator ies Inc.

Underwriters Laboratories Inc. authorizes the above named company to reproduce this Report provided its entirety.

it is reproduced in

File R6802-6A Page G 1 Issued: 6-5-78 GENERAL The subject of this Repor t is the fire resistance Classification of a W14X228 steel column protected with Type 330 mastic subliming coating applied to dry a film thickness'f 15/32 in. as described in the section entitled "Protection of Test Assembly," and as shown in ILL. 1.

The object of this investigation was to establish a fire resistance Classification for the column described herein by means of a fire endurance test conducted in accordance with the Standard for Fire Tests of Building Construction Materials, UL263 (ASTM E119, NFPA No. 251) .

In addition to the fire endurance test, the submittor r equested that we conduct an engineer ing evaluation of the tests de"cubi.bed in this Repor t and their column tests described in Repor ts R6802-3 and R6802-4, to determine the minimum dry film thic'kness of the Type 330 mastic coating necessary to afford a 3 hr fire resistance rating when applied to a W14X228 steel column. I F

The fir e test was supplemented'y other tests and examinations to furnish information regarding the composition and

,.physical proper ties of the mater ials used and to determine the practicability of handling and applying the coating.

GDP/RHB: plh

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File R6802-6A Page 1 Issued: 6-5-78 DESCRIPTION EXAMINATION OF HATERIALS:

The materials used in the test assembly are described below..

Column The column used in the test assembly was a W14X228 steel section measuring 8 ft, 3 in. long between the top and bottom concrete caps.

Primer The pr imer was a corrosion inhibiting modified alkyd pr imer manufactur ed by TSI, Inc.

Glass Fiber Gauze - The glass fiber gauze was embedded .in the mastic coating to provide reinforcement. The gauze was 12 in.

wide and weighed 1.70 oz per sq yd.

Mastic Sublimin Coatin The mastic subliming coating material was manufactured by TSI, Inc. (and designated Thermo Lag Type 330, The coating material was supplied in 55 gal steel drums. The mastic coating is*presently Classified by Under wr iters Laboratories Inc. under Follow-Up Service. The composition and other properties of the mastic coating are considered proprietary and are on file at the Laborator ies.

PROTECTION OF TEST ASSEMBLY:

The steel column was protected by workmen in the employ of the submittor under the obser vation of members of the Labor ator ies'taff.

The column surfaces were wiped with a solvent to remove surface contaminates. The primer was sprayed onto the column using an air gun.

The mastic coating, which wa's supplied in steel drums, was.

spray-applied to the column surfaces using. equipment designed for such purposes.

File R6802-6A Page 2 Issued: 6-5-78 The -mastic coating was applied to the column in several coats at thicknesses of approximately 1/32 to 1/16 in. Each coat was allowed to become tacky befor e the following coat was applied.

. After the coating. had been .-prayed to an approximate thickness of 13/32 in., the glass f iber gauze was pr essed into the coating over the entire column with adjacent sections of the gauze overlapped 1 to 3 in. The gauze was lightly rolled with a paint roller .

Approximately 3/32 in. of additional coat'ing was then applied to the column.

The coating was applied to a wet film thickness of approximately 1/2 in. as determined by several measur ements taken after spraying had been completed.

r The wet and dry densities of the mastic subliming coating were determined by applying the mater ial at a repr esentative thickness to a 2 by 2 ft steel plate. The wet density was obtained by weighing the plate immediately after spraying and the dry density was determined using the air dried constant weight of t'e steel plate and coating. The average wet and dry densities of the mastic coating were 85.8 and 61.2 pcf, respectively.'hile the mastic coating mater ial was curing, several in width from hairline to 1/8 in. formed at the crack'arying intersection of webs and flanges of the column. These cracks were repaired nine days after the spraying had been completed.

The final dry film thickness of 15/32 in. was determined on the basis of 108 measurements taken on the column 40 days after the spraying had been completed and the material had dried at r oom temperature to a constant weight condition. Individual thickness readings varied fr om ll/32 to 19/32 in.

The appearance of the column assembly before the fire endurance test is shown on ILL. 2.

GDP/8MB: plh

File R6802-6A Page T1-1 Issued: 6-5-78 TEST RECORD NO.

FIRE ENDURANCE TEST:

This test was conducted in accordance'ith the Standard of Underwriters Laboratories Inc. for Fire Tests of Building Construction and Mater ials, UL263 (NFPA No. 251, ASTM E119) .

DESCRIPTION OF SAMPLE.

Prior to placing the column assembly in the furance, several cracks were observed in the mastic coating at each web and flange intersection. These varied in width from hairline to 1/16 in. and were 1 to 2 in. long.

METHOD The column was placed in the furnace and exposed to flames of controlled extent and severity in accordance with the Standard Time-Temperature Curve. Eight thermocouples, distributed around the column in two levels as shown on ILL. 3, measured the temperatures in the furance chamber.

The temper atur es of the steel column were measur ed by 14 ther mocouples located as shown on ILL. 4. Thr oughout the test, obser vations wr e made to note the character of the fire, the condition of the exposed sur face of the column, .and all other data pertinent to the fire resistance performance of the column.

Character and Distribution of the Fire - The furnace fire was luminous and well distributed during the test, and the temperatures recorded in the furance chamber followed the Standard Time-Temperature Curve as defined in the Standard for Fire Tests of Building Construction and Materials, UL263, and as shown on ILL. 3.

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File R6802-6A Page T1-5 issued: 6-5-78 A summar y of the column test results included in this engineering evaluation is shown below:

Hater ial Occur r ence Of I Thickness, Limiting Temperature, Re ort In. Min + ~

R6802-3 5/32 77 R6802-4 1/4 127 R6802-6A 15/32 172

+ -'Limiting aver age cross-sectional temper ature of 1000 F used.

To deter mine the thickness of the mastic coating r equir ed for the 3 hr rating, a computer analysis of the above material thicknesses and time to reach the limiting temperatures was obtainyd. Based upon the resulting equation, Y = 0.00047 x it was determined that a minimum thickness of 1/2 in. would afford a 3 hr rating. The test data and the plot of the equation ar.e 1

shown on ELL. 6.

A safety factory of 8 percent (14 min) was used to determine the above thickness since the equation is an extrapolation of test data.

GDP/RMB

File R6802-6A Page Cl Issued: 6-5-78 CONCLUSIONS The following conclusions represent the judgement of Underwr iter s Laborator ies Inc'. based upon. the results of the examination and tests conducted in the Report, as they relate to established principles and previously recorded data.

FIRE RESISTANCE PROPERTIES:

It is judged that a 1/2 in. thickness of mastic coating, applied as described in this Repor t will afford a 3 hr rating when applied to a stc uctural steel column whose size is equal to ot greater than a W14X228 with- a minimum flange thickness of 1-11/16 in., a minimum web thickness of 1-1/16 .in., and a minimum cross sectional area of 67.06 sq in.

The assembly, in summa ized form as shown-:. on the individual design illustration included in this Report, will be illustrated in the Fire Resistance Directory as Column Design No. X611.

This Classification is based on the temperature limitations of 1000 F average and 1200 F maximum. allowable as'escribed under the ",Conditions of Acceptance" for structural steel columns of the Standard of Underwriters Laboratories Inc. for Fire Tests of Building Construction and Haterials, Standard UL263 (ASTH E119, NFPA No. 251).

The mastic coating and glass fiber gauze of the type used for

, this investigation can be readily applied to steel columns by exper ienced workmen using proper equipment. Materials and spraying procedures .in accordance with those described in this Report are significant factors in the fire resistance- of this constr uction.

CONFORMITY:

This construction was tested in accordance with the Standard for Fire Tests of. Building Construction and Materials, UL263 (ASTH E119, NFPA No. 251).

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File R6802-6A Page 1'ssued:

C2 6-5-78 FOLLOW-UP PROGRAM:

The mastic coating as descr ibed her ein is cur r ently covered under the Classification and Follow-Up Service of Unde>writers Labor atories Inc. Under the Ser vice, the manufacture er is author ized to use the Laboratories'lassification Marking on such products which comply with the Follow-Up Service Procedure and any other applicable requirements of Underwriters Laboratories Inc. Only those products which properly bear the Marking are considered as Classified by Laboratories'lassification Under writers Laboratories Inc.

The Classification Marking used on the mastic coating is illustrated, below:

UNDERWRITERS LABORATORIES INC. R CLASSIFIED MASTIC COATINGS FIRE RESISTANCE CLASSIFICATION DESIGN NO. X611 SEE UL FIRE RESISTANCE DIRECTORX

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M14X228 STEEL COLUMN t GLASS $ 'IBER GAUZE TYPE 330 ISTIC COATS'AG APPLXED TO A DRY FXLM THXCKNZSS OF 19/32 XN.

XLL. 1 R~8C2--6A

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('(i:."iE i:::.!lv Xoll A CARD RES ESTANGE RAT lNQS DESXGN NO. X611 RATING-3 HR.

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R 6802-6A

Guide BXUV June 5, 1978 Fire Resistance Ratings (X611-B Car d)

(Continued From X611-A Card)

I I'astic in Coatin s>> - Coating mixed thoroughly and spray applied sever al coats for a dry film thickness of 1/2 in. to column surfaces which must be free of dirt, loose scale and oil. Column sur faces to be (Itempr imed with a modified alkyd 2),pressed into coating pr imer'. Glass fiber gauze prior to application of final coat and lightly rolled in place with a paint roller. Coating may shrink causing cracks dur ing cur ing. These cr acks shall be filled with additional

- mastic coating.

TSl Inc. - Type 330. investigated for exterior and inter ior l use. For'xterior use, Type 350 top coat to be applied over mastic coating at a r ate of approximately 150 sq ft per gal.

G1-~ "s Fiber Gauze - Nominally 12 in. wide, 1.~70 oz per sq yd.

r 2. E:mbedded in mastic coating around entire col,'umn.

Steel Column - Hinimum size of column a MlNX228, with outside dimen-ions of 16 by 15-7/8 in., a- flange thickness of 1-11/16 in., a web th'ckness of 1-1/16 in., and a cross-sectional area of 67.06 sq in.

Bear ing the UL Classification Har king.,

I File R6802-6A Page C3 Issued: 6-5-78 Repor t by: Reviewed by:

G. D. PALIKIJ Engineering Assistant ~p'~~.o r

v.cc~

Fire Protection Department

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R.~ M. BERHINIG (

Engineering Group Leader Fir e Pr otection Depar tment SUBMITTED BY:

G. T. CASTINO Managing Engineer Fir e Pr otection GDP/RMB:plh

MONSAiITO MASTIC FL'3.YA E TUNNEL TEST REPORT The Insulative Performance of Experimental Formulations of Subliming Fire Re s is tant Coating 33 C -1 A re ort re ared for: ~

TSI ~ Inc.

3620 Brannon Avenue St, Louis, Missouri 63139 Special Report 8008

- Date of Test: March 16, )973 Monsanto Industrial Chemicals Company Special Chemical Systems Research and Development Department St. Louis, Missouri 63)66 Prepared bye D G. Schneider The information contained herein is true and accurate to the 3est of our knowledge and belief, but is transmitted without guarantee since the conditions of use are beyond our control.

Monsanto Industrial Chemicals Comoany disclaims any liability incurred in connection with the use of this information.

Furthermore, nothing contained herein shall be construed as a recomzr.cndation to use any product or practice any process in conflict with any existing patents covering any material or its use+

TABLE OF CONTE~aS Pa e Ão.

INTRODUCTI'ON ~ ~ e ~ ~ ~ e ~ ~ e ~ ~ ~ ~

- ~ ~ I-I SUM MARY ~ a ~ ~ ~ ~ ~ a ~ ~ e ~ ~ ~ ~ ~ ~ ~ ~ II-I DETAILS . ~ ~ ~ ~ ~ ~ ~, ~ ~ ~ ~ ~ ~ ~ IIX -I Subliming Fire Resistant Coating 330-1, Formulation No. 02131L on Large Beaxn, Nominal 350 mil Coating Table ble I ~ ~ ~ ~ ~ ~, ~ ~ Observation Notes Figure 1 ~ ~ ~ ~ ~ ~ ~ ~ ~ .Sample and Furnace Tempe rature Profiles Figure 2 ~ ~ ~ ~ ~ + ~ ~ Q Sample Illustrations IV MONSANTO MASTIC TES'XING FURNACE ~ ~ . ~ ~ IV-

I ~ INTRODUCTION This report describes the insulative performance of experimental formulations of subliming fire resistant coating 330-1 @(hen tested in a small furnace according to the time/temperature conditions described in ASTM EL19-67 ~

This. small Monsanto furnace test is intended to be used as a screening device for the development of insulative coatings. It is not intended to displace the large furnace test or evaluation of prop'osed products by recognized testing laboratories.

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SUMMARY

The coating was applied to a sandblasted carbon steel (ASTRA-52) column. The column was fabricated from two I>>beams~elded together to form a hollow rectangular core. The coating was applied and dried by TSI personnel before being submitted for testing.

The test column was subjected to the time/temperature conditions specified in ASTM E119-67 using the Monsanto furnace. This furnace is a modified version of the larger ASTM E119-&7 test furnace.

Substrate (steel column) temperature is monitored by six continuously

'ecording the rmocouples within the column core. These thermocouples are spaced at even intervals along the column length from S" to 38" from the bottom of the specimen.

A performance rating of 172 minutes was obtained for the test specimen on February 24, 1973 (see Table I for the Test Observation Notes).

Performance ratings are, in fact, the length of time between furnace ignition and the atta nment of,a 1100'F (593'C) substate temperature. At the time of failure, only one of the six substrate thermocouples had reached this temperature. The furnace and sample temperatures recorded during this test are illustrated in Figure 1. Figure 2 illustrates the condit:on of the specimen before and after testing

+Fabricated from 10-inch beams, modified and weldect to fora@ a rectangular core of 10" x 5-1/4" x 40"

I TA BLE I OBSERVATION NOTES: Subliming Fire Resistant Caating 330-1, Formulation OZ131I on Large Beam, Nominal 350 mil Coating Minu'. es Observations Upper half of cyluma beginning to darken with intumescence.

Ci. 1/8" of intumescence... some blisters.

P Some surface Gaming (quasi-halo effect).

14. Intumescence 1/4"-1/2" thick and plastic, teznperature rise ca. 6 C/

mine Intumescence 1/2"-3/4" thick and.elastic/plastic, surface flamin continues, temperature rise ca. O'C/xnia.

Surface beginning to whiten, Surface skin has become plastic/tough(rubbery) ~

Temperature zise ca. 4 C/min., intumescence 3/4"-I I/2" thick, skin is crushable (aot too hard), surface Gaming is lower, now 51 Surface nearly all white, and surface skin Cough/hard. ~ Tem erature empera ure rise ca 3'C/min.

Intumescence 1 1/4'~-? 1/4" thick and surface is hard (crushable).

83 Intumescence is ) 1/2"-2 1/2" thick (softer in flaages than on flats f)

Temperature rise ca. 2 'C/min.

Intumescence layer thickness unchanged, ~ but it is softeain ea ng.. eznperature rise 1 C/min~

101 ~

Intumescence 2 1/4"-3 1/2" thick(soft). Flange edges are thicMy I

covered with intuznes cence I I 11 Intuznescence? 1/2' - 4" thick 121 Intumescence 3"-5" thick, temperature rise ca. 2'C/znin.

128 The surface layer of intumescence has falIea aff of ca. 1/3 of the west side (not serious though siace it was anly ca. 1/?" !hick) ~

141 Iatumescence is unchanged, temperature rise ca. ? 1/? 'C/znin 150 Surface is degrading still xnore (aot serious though) ~ temperature rise ca. 3'C/min.

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TABLE K (Continued M/nutes Obs e r va tions 159 Large portion of intumescence fell away from top west side revealing a few sq. ia. of steel substrate, failure is eminent.

163 26<<TC reached 1000 'F, 172 Failure, 26<<TC reached 1100'F.

178 ... 26<<TC reached 1200 'F

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IU, MONSANTO MASTIC T STING r LB.NAC' Monsanto Industrial Chemical Company's mastic testing furnace ii a modified version of the larger ASTM E119-67 test furnace used by Underwrite r's Laboratories.'he furnace chamber ( 35" x 35" x 43")

contains a volume of ca. 30 ft~. Each of the four waLls has three gas burners, which are regulated to yield the standard time/temperature curve described in.ASTM E119-67. The furnace temperat re is indicated by eight thermocouples located within 1-Z" o: the sample spec'.men.

Sample temperature is monitored. by six thermocouples touching the

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metal substrate below the protective coating.

Attempts to correlate this furnace test with the ASTM E119 furnace have indicated that the Monsanto testing furnace ~ma be slightly more severe, Additional data is required to statistically define this correlation, however.

A more complete descrption of the Monsanto testing furnace will be the subject of a paper which will'be prepared and published in the near future

I

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Factoi"y,Mutual Reseals ch l

~ >g>r 4

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E EXPLORATORY PIRE E%)URANCE TEST OlL-STRUCTURAL STEEL COLUMN, J

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with

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THERIAC-LAG 330-1 COATD4G '.' i fox' JP 1 li TSX, IN'260 BRAiPiION AVEi ST+ LOUIS,: MO. 63139 SERIAL NO. 23187 CLASS NO. 4 970 NOVEMBER 30~ 1973

I GENERAL This reports results of an exploratory fire test conducted in the Factory Mutual High Temperature Furnace.

I The ob)ect of this test coating would afford t'o was to determine what protection the manufacturer's steel beams when exposed to temperatures noted below.

The test member was a 31 in. long W14 x 220 steel beam coated with Thermo-Lag 330-1. Thermocoupling and coating of the beam was done by the manufacturer at his plant and delivered to Norwood for test.

The tests were not conducted in accordance with any standard test method. The manufacturer requested the beams be exposed to a time temperature curve having the following characteristics: 0 min. ambient, 5 min. 1000'F, 10 min. 1300'F, 15 min. 1399'F, 30 min. 1550'F, 1 hr. 1700'F, 2 hrs. 1850'F and 3 hrs. 1925'F.

SAMPLE PREPARATION Six thermocouples were peened into a 14W x 220 steel beam. All were imbedded 1/4 in. Four into the 1-5/8 in. thick flanges and two into the 1 in, thick web. Those in the flanges were located less than 1 in. from the web. See Appendix A for locations.

The bottom and edges of the bottom flange were coated by the manufacturer with a hard surfaced white material identified by him as Thermo-Lag 330-1 to an average dry film thickness of 0.205 in. Remaining surfaces of the steel beam were unprotected.

FIRE ENDURANCE TEST AND RESULTS The sample was placed on top of the H4 High Temperature Furnace exposing the coated surface only to the firing chamber. The remainder of the beam was exposed to the ambient temperature.

Observations Durin Test:

Five minutes after ignition, intumescense began and white smoke issued from the coating. This smoking stopped at,30 min, No significant changes were noted until 2 hrs. at which time small pieces of intumesced material began flaking off for the remainder of the test. The flame was extinguished at 3 hrs. 1 min.

Furnace and steel temperatures are shown on the attached Appendix B.

~ os\ ~. ~

Observations After Test:

A few hours after the test, an examination of the beam showed approximately 50X of the coating had fallen into the furnace. The coating left was fragile and fell off readily when touched.

CONCLUSIONS Due to the exploratory nature of this test, and no conclusions can be drawn as to the it not being a standard test, coating's effectiveness.

Si~E/hh.

Pro)ect Engineer t ATTACHrD: Appendices A and B

I

/ /fwx22'g ~dc a j /earn ~ifh I+/8" hick Chirped, Bl" lang;

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Factory Mutual Research ~ ~

EXPLORATORY FIRE &(DURA FACE TEST on STRUCTURAL STEEL COLUiS with THERMO-LAG 330-1 COAT Ii'IG for TSI, IN'260 BRA'iNON AVE.

E ST. LOUIS, MO. 63139 SERIAL HO. 23187.1 CLASS itO. 4970 NOVEMBER 30, 1973

GENERA.

This reports results of an exploratory fire test conducted in the Factory lfutual High Temperature Furnace.

The object of this test was to determine what protection the manufacturer's coating would afford to steel beams when exposed to temperatures noted below.

The test member was a 31 in. long V14 x 220 steel beam coated with Thermo-Lag 330-1. Thermocoupling and coating of the beam was done by the manufacturer at his plant and delivered to Norwood for test.

The tests were not conducted in accordance with any standard test method. The manufacturer requested the beams be exposed to a time temperature curve having the following characteristics: 0 min. ambient, 5 min. 1000'F, 10 min. 1300'F, 15 min. 1399'F, 30 min. 1550'F, 1 hr. 1700'F, 2 hrs. 1850'F and 3 hrs. 1925'F.

SAMPLE PREPARATION Six thermocouples were peened into a 14M x 220 steel beam. All were imbedded 1/4 in. Four into the 1-5/8 in. thick flanges and two into the 1 in, thick web. Those in the flanges were located less than 1 in. from the web. See Appendix A for locations.

The bottom and edges of the bottom flange were coated by the manufacturer with a hard surfaced white material identified by him as Thermo-Lag 330-1 to an average dry film thickness of 0.205 in. Remaining surfaces of-the steel beam were unprotected.

FIRE ENDURANCE TEST Ai%) RESULTS The sample was placed on top of the FM High Temperature Furnace exposing the coated surface only to the firing chamber. The remainder of the beam was exposed to the ambient temperature.

Observations Durin Test:

Five minutes after ignition, intumescense began and white smoke issued from the coating. This smoking stopped at 30 min. No significant changes were .

noted until 2 hrs. at which time small pieces of intumesced material began flaking off for the remainder of the test. The flame was extinguished at 3 hrs. 1 min.

Furnace and steel temperatures are shown on the attached Appendix B.

Furnace< TGMpcpl'kai e Igloo o 0OO

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SoHew i. Ised 800 0arg C'srgpera I Ge= SX; ~nC.

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Observations After Test:

A few hours after the test, an examination of the beam showed approximately 50X of the coating had fallen into the furnace. The coating left was fragile and fell off readily when touched.

CONCLUS IOiiS Due to the exploratory nature of this test, and it not being a standard test, no.conclusions can be drawn as to the coating's effectiveness.

Slz/hh.

Prospect I) S.. VM.gh Engineer I AXTACMD: Appendices A and B I)

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7 $,2) >ice Sei..4o. PSr8 7 /

UNDER%'RITERS LABORATORIES LiNC.

Ql PFINiiTFI RtLEO 'rORBIRRAWi, ILl.l>AS t'r>Wl an i ndepenctent, not-for-profit o! <grani ation te8ting Jor public.~afet!t January 31, 1979 R6802"7 77NK7340 TSZ, Incorporated 3260 Brannon Avenue S t. Louis, MO 63139 Attention! Mr. Rubin Feldman, President Subjects Report On The performance Of A Steel Load Bearing Wall Assembly protected With a Mastic Coating During Fire and Hose Stream Tests Dear Mr. Feldmanc This is a Report on the performance of a steel walL assembly protected with a mastic coating during Fire and Hose Stream Tests -conducted in accordance with Standard UL 263, titled "Fire Tests Of Building Construction and Materials."

The test assembly consisted of a 1/2 in. thick steel plate with a WT18X85 vertical member and three NT6X18 horizontal members positioned as shown on ILL. 1 ~ The assembly was protected on all surfaces with a Classified mastic coating designated Type 330, manufactured by TSI, Inc.

DESCRIPTION MATERIALSt The materials used in the test assembly are described below.

Bearin Plate - The steel bearing plates were 15 in. vide by 9 t, n. ong by 1/2 in. thick.

Su rt An les - The support angles vere 3 by 3 by 1/2 in.

thick stee ang es 36 in. long.

L'ADER'l'VR(TERS LABORATORIES t.iC.

i R6802-7 Page 2 Jan. 31, 1979 Prefabricated Mall Assembl - The prefabricated wall assembly was a we ed stee section cons sting of a 10 ft by 10 ft by 1/2 in. thick steel plate with a NT18X85 vertical member and three NT6X18 horizontal members.

Primer - The primer vas a two-part inorganic zinc rich materiaT~esignated 90-92E manufactured by Tnemec Company, Inc.

Etb ~ig1.70 Reinforcement -

The reinforcement

qy was a 12 in. vide glass Mastic Coatin The subliming mastic coating material was manufacture y TSI, Enc. and designated Thermolag Type 330. The coating material was supplied in 55 gal steel drums. The formula-tion and other details concerning the manufacturing of the coating are on file at the Laboratories for use in connection with the Follow-Up Service Program.

ERECTION OP THE TEST ASSEMBLY:

The assembly vas iristalled by workmen in the employ of the submitter under the obse'rvation of members of the The appearance of the assembly during the installation Laboratories'taff.

is shown on ILL~ 2.

The steel bearing plates were attached to unistrut channels located in the sill and lintel of the test frame. The wall assembly was positioned in the test frame opening and the support angles were attached to the unistrut channels through the bearing plates. The assembly was then attached to the support angles with 5/8 in. diameter machine bolts and nuts. The assembly was attached to each support angle vith three bolts.

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The wall assembly was sand-blasted to remove surface rust and other contaminates and then coated vith the primer ~

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4'NDERA'R(TERS (.ABORATORlES INC.

R6802-7 Page 3 Jan. 31, 1979 The mastic coating was spray-applied to all surfaces of the assembly in a multi-coat procedure to approximately 75 percent of the final thickness at which point the glass fiber gauge reinforce-ment was applied over the entire surface, The coating was then trowel-applied over the reinforcement to the final design thickness.

The coating thickness was measured after the coating had dried approximately four weeks. -A summary of these measurements are contained in Table I.

TABLE I Number Of Minimum Maximum Average Measure- Thickness Thickness Thickness Location NTlSX85 35 16 26 18.6 NT6X18 32 28 19.0 1/2 in. plate exposed surface 48 11. 5 20 16.1 1/2 in. plate unexposed surface 69 '20.5 14.8 The appearance of the exposed surface of the assembly prior to the Fire and Hose Streaa Tests is shown on ZLI. 3.

R6802-7 Page 4 Jan..31, 1979 TEST RECORD NO ~ 1 FIRE ENDURANCE TEST:

This test was conducted in accordance with the Standard of Underwriters Laboratories Inc. for Fire Tests of Building Construction and .Materials, UL 263 (NFPA No, 251, ASTM E119) .

DESCRIPTION OF SAMPLE

The assembly was constructed as described in the preceding section of this Report titled "Erection of Test Assembly" and as shown on ILLS. 1 and 2.

METHOD The wall assembly was placed in front of the panel fuxw".co and exposed to flames of controlled intensity anQ severity with the standard time-temperature carve. Twelve ia'ccordance thermocouples, distributed as shown on ILL. 4, measured the temperatures in the furnace chamber..

The temperatures on the unexposed surface of &e c ssembly were measured with nine thermocouples, with each thermocouple covered with a 6 by 6 in. dry asbestos pad. The thermocouplos were located as shown on ILL. 5.

The temperatures of the HTLSX85 vertical member were measured with twelve thermocouples located ar. shown on ILX. G.

The temperatures of the HT6X18 'horizontaL members vere measured with nine thermocouples located as shorn on ILJ'i..7.

The temperatures of the 1/2 in. thick steel pEate at; die interface of the coating material applied to the expos'a'.c" avrf!ace of the assembly were measured with nine thermocouplee Lnca<e-',

on ILL. 7. ao'hown

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I R6802-7 Page 5 Jan. 31, 1979 The lateral deflections of the assembly were determined by measurements taken at the quarter and centerpoints along the

-horizontal centerline of the unexposed surface. The reference L line was a taut steel wire.

A compressive load of 100,000 Lb was applied on the assembly by means of seven hydraulic )acks. The magnitude of the load was specified by the submitter.

.The vertical movement of the loading beam was measured by two ex~nsometers placed near the north and south quarter points of the assembly.

Throughout the test, observations were made to note the character of the fire and its control, the condition of the exposed and unexposed surfaces and all developments pertinent to the performance of the assembly with particular reference to the stability, heat transmission, passage of flame and generation of smoke.

RESULTS Character and Distribution of Fire - The fire was luminous i

t and we xstr uted, e temperatures developed follow the standard time-temperature curve, as shown on XLL~ 4 and as i specified in the Standard.

Observations of the Ex sed Surface - The following observa-tions were ma e urging e re test. All references to dimensions are approximate.

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l. YDERA'R(TERS LAB()RAT()R!ES ti'C.

Jan. 31'979 R6802-7 Page 7 Observations of the Unex sed Surface -. The following observations were made during t e are test. All references to .dimensions are approximate.

Test Time, Observations 10 Small amount of smoke is rising from the top of the assembly.

30', No ma)or changes observed.

60 Small a~unt of smoke is rising from the surface near Thermocouple No. 4. This smoke appears to be escaping through holes in the coating made during the coating thickness measurements.

85 Small amounts of smoke rising from various points on the surface.

120 The amount of smoke rising from the surface is increasing.

140 The coating is bowing outward near the lower north portion of the assembly.

145 The coating is bowing outward at several locations.

160 The amount of smoke rising from the surface continues to increase.

181 Pire test terminated.

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R6802-7 Page g Jan. 31, 1979 t

Deflection - deflection of the assembly

~ 8 The e horizontal' \ bl TABLE II Hori,zontal Deflection - Inches Test Time Location Min OU enter Net 0 0 0 0 10 1/8 1/8 1/8*

20 1/4 3/4 5/8>>

30 1/4 1/8 3/8>>

40 1/4 1/8 3/8*

50 3/8 1/8 5/8>>

60 5/8 1/8 3/4*

70 1/2 1/8 1-1/8>>

80 3/8 1/8 1>>1/8*

90 3/8 1/8 1-1/8 100 1/2 3/8- 7/8*

110 5/8 3/8 7/8*

120 5/8 1/4 1-3/8>>

130 0 1/4 1-3/8*

140 5/8>> 1/8 1-5/8>>

150 ]>> 1/8 1-5/8>>

160 7/8* 1/8 1-7/8*

170 5/8* 1/8 2>>

180 5/8>> 1/8 2-1/8*

- Indicates movement away from the fire. All other readings indicate movement towards the fire.

R6802-7 Page 9 Jan. 31, 1979 The vertical deflection of the loading beam measured during the fire test is shown in Table IIX.

TABLE III Vertical Deflection - Inches Test Time, Location Min Sout 0 0 0 10 0.0034 0.002*

20 0.002* 0.001 30 0.008 0.013-40 - 0.027 0.032 50 0.045 0 '52 60 0.065 0.073 70 0 ~ 085 0.094 80 0.105 0.116 90 0 127 0.139 100 0.151 0.166 110 . 0.181 0.198 120 0.200 0.220 130 0;227 0 '50 140 0.252 0.280 150 0.280 0 '10 160 0 '05 0.340 170 0 '38 0.375 180 0.365 0 '05

- -Indicates upward movement. All other readings indicate downward movement.

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R6802-7 page 10 Jan. 31, 1979 Tem eratures of the Assembl - The initial average temperature o the unexpose sur ace was 77 P. Therefore, based on an average temperature rise of 250 P above ambient and a maximum individual rise of 325 P above ambient< the average limiting temperature was 327 P and the individual limiting temperature.was 402 P.

The'temperatures of the unexposed surface are shown on ILL. 5. The average limiting temperature occurred at 138 min and the individual limiting temperature occurred at 160 min.

'n The temperatures of the WT18X85 vertical member are shown ILL. 6 for general information purposes. At, 180 min, the maximum average cross-sectional temperature was 955 P and the maximum individual temperature was 1070 P.

The temperatures of the N6Xl8 horizontal members are shown on XLL. 7 for general information purposes. At 162 min, the maximum average cross-sectional temperature was 1000 P and at 168 min, the maximum individual temperature was 1200 P..

--The. temperatures of the X/2 ii. thick steel-plate~measured,,

I

~-=

at the interface.",of'he;coating. material apgied, on'the"exposed;,.;"-:,.

surface of the assembly and the. sted. plate are'hown on. ILT',V."<

for- general: informati.on. purposes- 'At 180=min~, the average;--:-;-.;.'..

I temperature"waa V3$' and; the,maxhaum individual--temperature: wa'g,

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L'ADER'L'FR[TERS LAB'OftkTOR[ES IYC.

R6802-7 page Jan.

ll 31< 1979 HOSE STREAH TESTc Immediately. after the fire exposure, the assembly was with-drawn from the fire and the exposed surface was sub)ected to the impact> cooling and eroding action of a water stream app1ied with a 1-1/8 in. nozzle at 30 psi pressure from a distance of 20 ft for a period of 2-1/2 min.

During the Hose Stream Test, the coating material applied on the exposed surface was eroded away. The remaining portion of the

.assembly remained in place and the hose stream did not penetrate through the assembly.

OBSERVATIONS AFTER THE TESTS!

The appearance of the exposed and unexposed surfaces of the assembly after the tests are shown on "ILLS. 8 and 9, respectively. P On the exposed surface, the coating material applied to the 1/2 in. thick steel pl'atc and the exposed flanges of the NTLSX85 and NT6X18 members was eroded away from the steel surfaces during the Hose Stream Test. The coating materiaL remained on the webs and inner fLange surfaces of the NTLSX85 and WT6XLS members.

On the unexposed surface, the coating materiaL delaminated from the steel plate in many areas, resulting in voids between the coating material and the pLate. The maximum depth of the voids was approximately 2 in. The color of the coating material was darker underneath each asbestos pad as compared to the .

remainder of the material on the unexposed surface.

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L'iDFRiVR(TERS LABORATORlES lb'C.

R6802-7 Page 12 Jan. 31, 1979 I S UMHA RY Because you do not desire a formal Report to be published I nor the tested assembly to be Classified in our Pire Resistance Directory, we are closing Assignment 77NK7340 with this Report and instructing our Accounting Department to invoice you for the final charges.

Very truly yours, maZ ROBERT Mo BERHINZG Engineering Group Lea r Pire Protection Department Reviewed by<

~J gl gga!! ~88(

K o W, HOWELL Associate Managing Engineer Pire Protection Department RMB!DB

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UNDEREVRlTERS LABORATORIES INC.

N Prlh(isTEX R0%n ','<ORTHBNOOh. Il,l I NOls 6&b'2 an inrtepenclent, not-for-profit o> gani:ation testing for public safety April 1, 1981 R6802 81NK4969 TSI, Inc.

3260 Brannon Ave.

St. Louis, MO 63139 Attention: Mr. Rubin .Feldman President

Subject:

Exploratory Small-Scale Fire Test

Dear Mr. Feldman:

This letter will confirm that an exploratory small-scale fire test has been conducted on a test sample consisting of a 5/8 in. thick steel plate covered with two layers of 1 in. thick rigid fiberglass form boards and 0.3 in. of Type 330 mastic coating. A fiberglass cloth, weighing 1.70 oz per sq yd was embedded in the mastic coating.

The test was conducted to provide TSI, Inc. with unexposed surface temperature data to help evaluate the above products for future ULI Classification.

The unexposed surface temperatures of the small-scale sample were measured by ten thermocouples, each of which was covered by a 6 by 6 in. dry asbestos pad. The thermocouples were installed by a representative of TSI, Inc.

The furnace temperatures, as measured by three symmetrically located thermocouples placed 12 in. below the exposed surface, followed the Time-Temperature Curve, as outlined in Standard UL 263.

The limiting average unexposed surface temperature (321 F) occurred at 228 min (3 hr, 48 min). The limiting individual temperature (396 F) occurred at 272 min (4 hr, 32 min) .

The fire test was terminated after 300 min of exposure.

Look For The @Listing or Classification Mark On The Product

U iNDERA'RITERS LABORATORIES INC.

R6802 Apr Page il 1, 2

1981 We have enclosed the unexposed surface temperatures represented both graphically and in tabular form.

This letter 'completes our anticipated work on Assignment 81NK4969 and we have instructed our Accounting Department to bill TSI, Inc. for the charges'ncurred.

Very truly yours, L L Y@~ ~ -:Lb GERALD D. PALIKIJ

.till,.

~J Senior Engineering Assistant Fire Protection Department Reviewed by:

B. SWYTNYK Engineering Group Leader Fire Protection Department GDP:pr

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W W W W W W W W W W W W W W W W W W UNEXPOSED SURFACE TEMPERATURES TSI, INCORPDRATED DEGREES, F NNINI IML TBPEfQTURE I

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I AVERAGE TEHPERATURE j

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I gl' 8 15 % 45 68 75 98 185 128 135 158 165 188 195 218 225 248 255 278 285 388

, -TIHF BIN.

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0 7'3 'i 77 78. 8 S 84 8 82 85. 1 30 89. 9 96. 4 90. 9 35 94..9

ino. 7 40 98.4 104.1 98.8 100.6 45 iai 103.2 107 102. 1 104. 5 104 106.9
)0 5'5 105.7 iii.
1O9. 3 4 106. 9 109.5 bn 6S 70 iii 108.3 5.5.3. 9 i i3.
1 1 ii8.
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1 109. 3 111. 7 114. 3 112 2 115 118 75 117. 1 120. 9 117. 2 121.3 80 120.4 i24. 3 120 125 85 124 128 124 2 129 9n. 5.27. 7 132. 3 128. 1 133.3 95 131.8 137 132. 2 137.7 100 13*. 2 142 2 136.6 14P.. 2 105 141. 2 147. 6 141.1 146. 8 iia 115 146.
15p 4 153. 3 159 146.
151.
151. 9 157. 2 120 157. 6 164. 5 156. 3 162. 7 125 130 163 168. 4 169.8 175. 4 ibi. 6 167. 1 168.1 174. 5 135 174. 9 .183. 4 172. 8 182. 6 14a 181.8 191. 2 179 191. 9 145 189. 2 -199. 1 186. 2 ai 150 5.96. 8 207. 4 193. 8'7 210. 3 155 204.2 215. 7 201. 219. 5 160 211. S 223. 8 209. 8 228. 3 ibS 218.6 231. 9 217. 6 237. 1 170 239. 8 225 "
245. 3 175 231. 8 247. 6 232. '7 253.3 180 185 190 19S 200 205 210 215 0'0 0
238 243. 9 249. S 255 260. S 265. 8 271.1 276. 2 281. 1 255.3 262. 8 270. 1 277. 3 284. 3 291.3 298.2 304. 7 311. 1 246. 7 Z53. 2 2S9. 6 265. 9 271. 9 Z77.8 283. 5 289.1 260. 8 Z67. 9 274. 7 281. 1 287. 1 29Z 303. 5 308.4 3
9'98.
286 317.5 294.6 313.1 230 290.9 323. 299. 317. 5 235 P95. 6 329' 7 305 9
321.6 240 300.3 335. 3 309. 8 32S. 4 245 3a 4.'7 340. 9 314. 4 329 250 309.2 346. 2 318. 8 332.5 255 313. 6 351. 5 336. 1 260 317.9 356. 3 327 339. 4 265 322 2 360. 9 330. 9 342. 7 h70 326. 2 365. 3 334: 6 346. 1 275 330.1 369. 9 349. 5 280 334. 1 374. 5 353 285 338 378.7 345. 9 356.3 290 341.8 383 359.9 295'0 345. S 387.1 353. 3 363. 2 348. 9 390.7 356.8 366. 5 TABLE NO. 1
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230 300.8 304.9 318. 5 301.9 3(5.5 323. 1 306. <':?
319. 0 308.8 327. 6 310.'3 323. P 250 31<~. 5 33$ . 7 314. 2 255 316.3 335. 6 317. 9 330. 8 320 339. 5 321. 6 334. 2 260 323. 7 343. 4 325. 2 337. 6 265 327. 2 347. 2 328. 8 340. 9 270 331 351. 1 332 '!'>>
275 334. 8 355 336. 2 347. 6 280 338. 7 359 339. 9 351.1 285 342. 6 363 343. 7 354'5 290 346. 3 367 347.4 357.8 295 350 ,"370 . 8 361. 2 300 353. 4 374. 2 3*4 (
TABLE HO.
TSI, INC.
CHAN(NQB.)
TINE (HIN . )
5 70.8 71. 9 71. 9 71. 8 10 71.8 72.8 73'. 7 73 15 75.8 76 78. 6 76. 6 20 81.7 80. 5 85 2 80. 9 25 88.7 86. 9 91.3 86.6 30 95.6 93.8 96.8 92.7 35 101.1 99.7 101.7 98.8 40 1 05.6 104. 5 105.5 103.2 45 109 108 108.5 106.4 50 SS ffi.h 113. 9 110. 7 i115.
f3. 2 ifi.2 113.7 109 111.5 60 116.2 5 116.1 114. 1 65 70 ii8.6 121.2 118. 1 121 118.8 121.9 116.8 119. 8 75 124. 3 124. 3 125. 4 123
80. 128 128.1 129.3 126. 8 85 132. 2 132. 3 133.7 130. 9 90 136. 8 136. 7 138.8 135. 7 95 100' 141.6 141. 4 144. 7 ~
'141.3 f 47.3 146. 4 151.3 147. 9 1,05 153. 6 f52 158. 1 155. 2 110 160.5 158.3 165 162. 5 115 167. 4 164. 7 171.9 169. 7 120 174. 3 171. 3- 178.8 177. 6 125 . 182. 7 179. 4 187.4 186. 9 130. 192. 2 189. 1 198.7 209.'9 196.9 135 202.5 199.3 207. 2 140 213.2 209.9 220.7 2f7 2 145 223. 8 220.7 231.3 227 .
150 234 231 241.6 236.5 15S 243.9 240. 9 251.6 24S.b iba 253.5 250. 5 261.2 16'I 262.8 259. 7 270.5 262.8 271. 8 268. 5 279.5 270.8 175 280. 5 277 288. 1 278.5 180, 288. 7 284.9 296.2 285. 7-185 296.6 292.5 303. 292. 6 304.4 299. 4 i9s 311.9 50$ .4 9'sh:3 306. 2 200 319.3 325. 7 312, 7 205 326.3 zaz'.5 332 318.9 337.8 324. 8
39. 7 328. 9 343.1 330. 4 220 346. 333. 8 348 335. 9 225 2 1'52.
338. 4 352.4 341 230 358 342. 6 356.7 345.8 363 6
~ 346. 7 360.5 349. 9 368. 9 350. 4 364.2 353.8 245 373. 8 353. 367.8 357. 4 250; 378. 4 4 9'57.
371.3 360. 9 382. 6 360. 9 374.9 364.3 260. 386. 4 364. 2 378.5 367 8.
371'. 2
~
265'70 390 367. 6 382 393. 5 370. 9 385. 8 374. 6 275 397. 2 374. 5 389.6'7 378. 1 280 378. 393. 381.
28S 4O4') . 6 i'8i 397.6 4 9'8S.
290 408.6 385. 1 401.4 388. 9 29S 412. f 388. 6 405 300 415.2 391. 6- 408.2 TABLE HO. 3
I I
I I
I L
i I
I
TINE IN HIN.
5 71. 175 io 72. 1417 15 75. 3333 20 80. 05
85. 8417 30 9i. 8917 35 97.i 40 101.208 45 104.i92 50 1 06. 633 55 108. 992 60 1 1 1; 433 65 1 13. 992 70 116.808 75 ii9.958 80 123.533 85 127.45 90 131.775 95 136 . 558 100 141.908 105 147.7 110'. " 153.833 115 160 . 042 120 166.258 125 172.942 130 180 .375 135 188. 658 140 197.425 145 206.408 1 50. 215.342 1SS 224.058 160 232.575 165 240.842 170 248.75 175 256.4 180 263.692 185 270.625 190 277.342 f95 283.867 200 290.158 205 29b.,iS hfo 301.925 215 307.4 220 312.692 225 3i7.792 230 322.65 235 327.2 240 33i.55 245 335.633 339.608 93 260 343.517 347.283 265 350.967 270 354..658 275 358 '08 280 .362.275 285 366.008 290 369.742 295 373.'333 300 376.6
THREE. HOUR FIRE ENDURANCE TESTS ON TSI'S CONFORMABLE THERMO-LAG 330 -STRESS SKIN FIRE WALL ASSEMBLY PRELIMINARY REPORT JUNE 1981 4 3260 BRANNON AVE. 4 ST. LOUIS, MO. 63139 ~ (314) 352-8422 4 Telex'-44-2384 TSI, INC.
THREE HOUR FIRE ENDURANCE TESTS ON TSI'8 CONFORMABLE THERMO-LAG 330 STRESS SKIN FIRE WALL ASSEMBLY GENERAL:
This reports the results of a fire simulation test conducted at TSI's ASTM E119 Fire Simulation Facility. The objective of this test was to determine the degree of fire resistance to flame penetration protection offered by TSI's THERMO-LAG 330 Conformable Stress Skin Fire Wall Assembly.
FIRE TEST AND RESULTS:
The test member was 4'ong x 4'ide. The Stress Skin was centrally located with 0.695 inches of THERMO-LAG 330-1 Subliming Coating on the fire and non fire side. The instrumentation of the test articles consisted of 9 thermocouples symmetrically located on the exterior surface of the no flame side of the test assembly. Each of the thermocouples were covered with 6" by 6" dry asbestos pads'he facility tempera-ture was measured by 9 symmetrically located thermocouples placed 12" away from the exposed surface of the test assembly.
The limiting temperature of the unexposed surface of 320'F
occurred at 207 minutes. The limiting individual temperature occurred at 220 minutes at which time the fixe test was terminated. Visual observations during the test have clearly shown that there was no penetration of flame through the test assembly at any time during the fire.
The test procedure followed prerequisites of ASTM E119 Time/
Temperature Environment and IEE 634 entitled IEE Standard Cable Penetration Fire Stop Qualification Test. This is a preliminary report. A detailed report is being prepared and will be submitted shoxtly.
I'
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,5155 S$ 55555555555k5
ASTM E119-73 FIRE ENDURANCE TEST (MODIFIED)
STRUCTURAL STEEL COLUMN PROTECTED BY 'QlERMO-LAG 330-1 COATING DESIGN CT-36 for T.S.I., INC.
3260 BRANNON AVENUE ST. LOUIS, MISSOURI 63139 SERIAL NOo 23160.1 (CLASS FILE 4960)
APRIL'974 iFactory Mutual Research 1151 Boston- Providence Turnpike Norwood, Massachusetts 02062
SECTION II SIMULATED POOL FIRE TEST ON THERMO-LAG COATED PLATE 1/8 INCH
SlNULRTED POOL i/B N.
F lRE TEST 3t dBH 1ST8 ON TSl CORTES PLflTE r
IHH Q
l8 28, 38 'l8 K'8 GH 78 88 98 188'l8 II T LEE cNlN>
~ IHI ILRTEII Pl II IL FI,:E TE': 1."':-: IH. T:: I-C0RTED PLRTE i CHRHHEL HO. TEHP (F.)
5Q T I HE Q, 6? 1 (H IH) 1 , iOQ ,,5Q 15Q- 6. Q46 1 'vQ 9.::-:4v 1 '"50 14.542 1 2Q.f78 1 25.671 1 '~30 3Q.355 1 45Q ::-:4. 3? 1 1 iAQ ~ tg27 1 -55k3 44.190 1 6vQ 55. Cll 1 65Q 72 v?5 e 1 679.Q 1C~r3. QQQ
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FIRE TEST: ir'8 IH. 'TS.I-CGRTED PLRTE 31 JRH 1977 RHHEL HO. TEHP <F) ~
TINE (t)IH)
C 5A 0. 690 10Q Q48 15Q 6;284 200 1Q. Q513 5 25Q
- .14. 460 5 r1r1 1 9 ~ Q85 5 35Q 23a 2t'8 C'
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15. 276 i ' 341 Q 350 4QQ 21 5r1
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27.499 32.521 1
450 37. '="70
45. 906 co'A 64. 748 611r1 ~ @13 611 r ~ 7 1Q0. QQQ
1 "='H ~ T':!-CGATED PLATE "1 JAtl i977 t CKRHtlEL t<0.
i TEt1P 5A (F) TItlE (NIH) l3. 671 1 l3U ~ o~iQ s sc L 15Q 6. A96 AQ 9. 84Q 25Q 14. 542 1 ~
8Alj 20. 178 1 85A 25. 671 i 4Ul3 8Q. 855 1 45Q 34e87i 1 5AQ 88 627
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V1 l3. 676 1l3l3 2 i5Q 6. 776 2 QQ 11. Q88 2 8QQ 2l3e Q78 a s.,tj 24. l367 Pj I 4QQ 27. 622 45U 'il3 ~ 754
. iUQ r> c c l,1 87.448 L
Pp 6Ql3 4i.975 65A 49.254 2 7UV 75Q. 75.654 L 77Q. i 10Q. l3l3Q 1.HAHHEL tlG. TEHP (F) T I HE ( t'I IH) 4 5U lj, 6~e5 1 Ql:1 2. 96o L cc9
'lj 15Q 25Q
11. 168 17.818 8QQ =" l3oi
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=: IHULATED POC1L F IFE TEST: f.i8 It). TS I-CUATE"1 F LATE 31 JAH 1977 L
ChAtOt t'L HO. TEHP (F) TINE (HItt)
~
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1 5C1 5 ~ 9'4 0J I '" 811 er 565
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~
45A 29. 19S L 9 ,OG 32. 669 55i 81 36.689 6C1 C1 41. 522 L 65O 48.792 9 7GC1 61.296 p 75U 7V. 532 e te L p
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I SECTION III SIMULATED POOL FIRE TEST ON THERMO-LAG COATED PLATE 3/16 INCH
g
~
SlNLlLBTED POOL FlRE TEST. OW TSl-COBTED PLRTE 3llG ill 3 FEB l977 Pl z.
BHH 0 Pl 3J 4J 7 688 K Pl K l S 288 lHH tL El Z
fJ 8 lH 28 38 RH KH 68 78 88 BH .l88 t l8 T LME,CMLN>
y g!!i el
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19. 717 i v ~
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$ .'HAHt/EL HO. TE!'!P (F r TItlE (O.'H:
CQ $3, ','$ 14 3 1 $ 1Q ':-'18 I
15$3 tg ~ ci$ $3
. $3 $3 1Q, ~$3. i 1C . s ~
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'='5V 1' 708 3V$ 1 f8. 453 35 1'1 2 is V 49.585 411i1 45V 70 r 51jQ CHRHH~L HU. TErlP (F) T I HE ( kl I H )
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parsi =:i =~ cat L:HHt(tfEL t II, 'E"!P c F;. TI fsf <<flirt~> ssT. s> td +<a s5 e~
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SECTION IV .
SIMULATED POOL FIRE TEST'N THERMO-LAG COATED PLATE 1/4 INCH
m m,m w m m m w m m m 1 SIHULBTED POOL FlRE TEST QH TSl-COHTED PLRTE lHHH lA N. Z rCS lan P,l z
BHH 13 Pl 23 33 EHH Pl lt 2
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SII'lULRTED POOL FIRE TEST: 1'4 IH. TSI-CORTED PLRTE 2 FE8 1977 CHRHHEL HO.= T Et'IP (F ) T I I'1E ( fl I H) 2 58'88 2o 637 2 9. 746 2 158 16.485 280 27 343~
250 45. 583 2 3I 18 58.27S 2 358 74. 944 2 488 89.898 GHRHHEL HO. TEt'1P (F ) TI tlE (t'1IH) 3 50 2. 568 3 188 S. 961 3 158 15.481 28Q 25. 419 3 258 41.642 3 308 56.167 3 8 72.239 3 400 86 '46 CHRHHEL HO. TEflP (F) TINE (HIH) .
5 58 2. 814 5 188. .7. 588 5 158 13.4?4
. 5 288 . 23.646
5. 258 36.813 .
5 388 56.418-.
.5 358 81;-989-5 4QQ 98.269
SECTION V FULL SCALE TANK CAR TESTS
DEPARTMENT OF TRANSPORTATtON t FEDERAL RAILROAD ADMINISTRATION sr
~r 0 WASHINGTON, D.C. 20590
~~ALIIS 0S gUN 24 19T7 Dr; Rubin Feldman President, TSI'nc.
3260 Brannon Avenue St. Louis, Missouri 63239
Dear Dr. Feldman:
In response. to your request for torch data generated on a tank car equipped with nominally. 165 mils of your material, I'm enclosing:.
a) Data from a bare tank car torch test.
b) Full Scale Torch Test 'data on TSI - coated tank car (nominal thickness 165 mils--August 25, 1976).
If you have any questions regarding this data, please feel free .to contact me.
Sincerely, n Levine Chief, Rail Vehicle Safety Research Division Enclosure
SECTION VI BARE TANK CAR TORCH TEST
BRRE TRNK CRR: . TEST 43 f')~ f Q lg ~ gQ QQ f',
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TEST 43 l!MN YERTIGL RON IF, T.C.
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M W W W M ERRE TRNA CRH: TEST 43 F'lRST VERTlQR. lKN Gf'.<. l288 Pl z
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BRRE TRNA CRR:. TEST f3
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DOT FIRE HOSE WATER IMPINGEMENT TESTS
DOT FIRE HOSE WATER IMPINGEMENT TESTS 4
DOT FIRE HOSE WATER IMPINGEMENT TESTS
I~
cicely Mutual Big,seal ch 1151 Boston-Providence Turnpike Norwood, Massachusetts 02062 i 23160.1 April 1974 ASTM E119-73 FIRE ENDURANCE TEST (MODIPIED)
STRUCTUEVJ STEEL COLUMN PROTECTED BY THERMO-LAG 330-1 COATING e DESIGN CT-36 i for 11 T.S.I., INC.
3260 BRANNON AVEZRE li ST. LOUIS, MISSOURI 63139 GENERAL This report describes the construction, the test procedure and the results of a fire endurance test conducted on a W10x49 structural steel column protected by Q.217 in. thickness of Thermo-Leg 330-1 coating as shown on Illustration l.
The object of this test program was to determine the performance of a column member protected by a coating conforming in quality and physical properties to those herein described. A fire endurance test was conducted on the protec-ted column member under steel temperature limitations in accordance with the Standard for Pire Tests of Building Construction and Materials ASTM Designa-tion E119-73, (NFPA No. 251) with the following exceptionss
1. The 5 ft. length of the column tested was less than the required 8 ft.
2~ Two levels of four thermocouples were used to monitor the temperature of the steel column in lieu of four levels of three thermocouples.
The test was conducted at National Gypsum Company using their furnace design to meet the requirements of the ASTM E119 Standard for the evaluation of floor-ceiling assemblies. The height of the column tested wae restricted due I
to the depth of the furnace chamber.
The column assembly was subjected to a fire exposure for a duration of 2 hours2.314815e-5 days 5.555556e-4 hours 3.306878e-6 weeks 7.61e-7 months and 8 minutes.
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FACTORY MUTUAL RESEARCH CORPORATION Page 2 23610 1 DESCRIPTION The materials used in the construction of the protected column assembly are described below:
Column The steel column was a W10r49 struotural member 5 ft. 6 in. long and when installed in tha furnace hed an effective length o! 5 ft .as measured from the furnace floor to the underside of the concrete cap. The concrete cap was 5 in. thick by 20 in. square. The cross-sectional dimensions of the column were 10 by 10 in. with 9/16. in. thick flanges and 3/8 in. thick web.
~Cootie - The coating material was manufactured by Tgl, Inc. snd designated as Thermo-Lag 330-1. The product is a water base intumescent coating material of subliming characteristic. The material was furnished ready for uses Thermo-Lag 330-1 was supplied in 55 gal. containers snd weighed approximately 9 lbs/gal.
Coatin Reinforcin - Glass fiber mesh 28 in, wide stzips cut 24 in. long and weighing 1.88 oz/yazd. The mesh was wrapped completely around ths column following its contour being installed between applications of the Thermo-Lag 330>>1 coating.
PREPARATION Op COLUMN ASSEMBLY:
Eight thermocouples were attached to the steel column, four at each level as shown in Illustration 5. The wire, used for the thermocouples, was No. 20 B6S gage iron-constantan with an enamel and felted asbestos insulation.
Through holes were drilled in the steel and one lead of the thezmocouple wire was pulled through until its )unction was at mid-thickness of the steel and then the steel was peened to close the opening.
The protective coating was appLied as shown on Illustrations 1 through 3.
'he column member first received a brush coat of TSI, Inc. 220 Primer applied at a thickness 0 003 in. and allowed to set for one day. The column then received two spray applied coats of Thermo-Lag 330-1 on two successive days which resulted in a total thickness of 0,160 in. After a one day set period, the column received a brush coating of 330-1 thinned with water to,the oasis-tency of thick paint before applying the glass fiber cloth. The mesh cloth was placed horizontally around the column following its contouz. The ends of the strips were butt-pointed at each side of the column web while the sides
-overlapped the ad]scent strips 1 in. The mesh cloth covered the entire height of the column. h second coat of the thinned 330-1 was brushed on.
The next day a third coat of Thermo-Lag 330-1 was sprayed applied. The dry film thickness of the overall coating was in exc ss of the desired. By use.
of an automotive type body grader, the coating was removed so that the overall coating was an average of 0.217 in. thick after an additional brush coat of water-thinned 330-1 was applied.
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I
FACTORY MUTUAL RESEARCH CORFORATIOH 23160. 1 Page 3 FIRE Pi<DURANCE TEST The test was conducted in accordance with the Standard for Fire Tests of Building Construction and Materials ASTM Designation E119-73 (tPPA No, 251) with the exception that the column was 5 ft. in length and were instrumented with two levels of four thermocouples. The Standard specifies a minimum length of 8 ft. and four levels of three thermocouples. The National Gypsum Company equipment for the testing of flame ceiling assemblies was used for this test.
SA.PLE:
The column member tested was described under Preparation of Column Assembly.
KTHOD:
The column assembly was placed in the floor-ceiling furnace as shown in Illustration 4 and a fire rated ceiling system was installed over the full furnace opening. The temperature of the furnace chamber was measured by 14 thermocouples which were placed 4 ft. above the base of the column and loca-ted as shown in Illustration 5. Thermocouples Nos. 9 and 12 did not function.
The temperatures of the steel column were recorded at 8 locations as shown on Illustration 6. The ASTM E119 Standard states the limiting end point tempera-tures are reached when the average temperature of the steel at any one level exceeds 1000'P or if any single temperature exceeds 1200'P.
Throughout the test, observations were made to note the character of the fire, condition of the column protection, and all other data related to its fire resistive performance.
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I
FACTORY MUTUAL RESEARCH CORPORATION 23160.1 Page 7 CONCLUSIONS A fire endurance test was conducted on a W10x49 structural steel column protected by a coating 0.217 in. thick of Thermo-Lag 330-1. The protected column was sub)ected to fire exposure for a duration of 2 hours2.314815e-5 days 5.555556e-4 hours 3.306878e-6 weeks 7.61e-7 months and 8 minutes.
The test was conducted under steel temperature limitations in accordance with the Standard for Fire Tests of Building Construction and Materials ASTM Designation E119-73 (NFPA No. 251) with the exception that the column was 5 ft. in length and was instrumented with two levels of four thermocouples.
The Standard specifies a minimum length of 8 ft..and four levels of three thermocouples. The limiting end point temperatures are reached when the average temperature of the steel at any one- level exceeds 1000'F or if any single temperature exceeds 1200'F.
The protected column assembly as. tested met the requirement of the Standard for 90 min. after fudging Thermocouples No. 6 and 8, used to monitor steel column temperatures, were functioning improperly.
At two hours of exposure only two 'thermocouples were functioning. The tem-perature measure at this time was 550'R and 595'F. It is Factory Mutual's opinion based on the condition of the coating that had the thermocouples not deteriorated, this column assembly as tested would had satisfied the require-ments for two hours.
LABORATORY RES PONS IBILITY The Factory Mutual Research Corporation makes no )udgement of product uniformity solely as a result of the ASTM E119 fire tests. Product uniformity depends in part on manufacturing facilities and procedures which would be inspected by Factory Mutuals Quality Assurance Follow-Up Inspection Program and on a written agreement put in force between both the product manufacturer and Factory Mutual.
Unless these conditions are met, the product can not bear the Factory Mutual name in its advertising.
Page .8 FACTORY MUTUAL RCSEARCH CORPORATION 23160.1 ILLUSTRATION 1 I
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23160. 1 FACTORY MUTUAL RESEARCH CORPORATION Page 9 ILLUSTRATION 2 SPRAY APPLICATION OF THERMO-LAG COATING (3259-1)
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ILLUSTRATION 3 CLOSE-UP OF GLASS FIBER BETWEEN COATINGS (3259-2)
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Page 1.0 FACTORY MUTUAL RESEARCH CORPORATION 23160.1 ILLUSTRATION 4 COLUMN ASSEMBLY BEFORE TEST (3259-3)
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23160. 1 PACTORY MUTUAL RESEARCH CORPORAllON Page ll FURNACE TEMPERATURES FIRE ENDURANCE TEST JULY 5, 1973 TSI~ INC ~
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)t1' 23160. 1 FACTORY MUTUAL RES jARCH CORPORATION Page 12 COLUMN STEEL TEMPERATURES FIRE ENDURANCE TEST JULY 5, 1973 TSI$ INC ~
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23160. 1 FACTORY MUTUAL RESEARCH CORPORATION Page 13
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ILLUSTRATION 7
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I Page 14 FACTORY MUTUAL RESEARCH CORPORATION 23160.1 Test by.'ire Technology Group National Gypsum Company Design CT-36 Technical Supervision of Construction and Pire Test by:
W. R. Price Engineer Factory Mutual Engineering Association Report by:
W. P. Shield Engineer Factory Mutual Research Corporation
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DEPART% EMT OF TRANSPORTATlOH FKOEIRAL, RAttRO~ AQ&lHlSTRAT(CW NAkrlIPe4fOit, 4 C NOOO
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pj's 1585 Or. N. Fel&ao TSI Inc.
3260 Brannon Avenue St. Loufs, Hfssourf 63)39 Qoar Hr. Feldman:
In reference to your letter ef Oece+er 10, 1975.'eqvestfny test data perlonied on TSI-Thermolay 330-I I have asked the 8allfstfc .
llesearch Laboratory. to furnfsh you ef Q the copy Of Report 1lo.
459. The results ot tests conducive& on a variety of ne'.erfall
. fn at.'&ftfon to yours are represented fn the report. The data fs fn code. Your materfal fs,coded C-2, and the dfscussfon of the resu)ts of your raterfals itart on pige 46 of the report.
If you have any addftfonal questfons concernfnl the reported AtI, feel free to contact ee.
'fncerely, Don Lcvfne Actfny Chfef, Rafl Vehfc)e Safe> Rcseareh Nvfefoe
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I TABLE OF CONTEiJTS I l SECTION I I Comparison of Insulated Tests With and Without THERMO-LAG (C-2 Coating) 1/8 Inch Thick I Fire Hose Wa te r Tes t.
SECTION II Simulated Pool Fire Test on THERMO-LAG Coated Plate 1/8 Inch SECTION'II Simulated Pool Fire Test on Coated I Plate 3/16 Inch THERMO-LAG IV I SECTION Simulated Pohl Fire Test on THERMO-LAG Coated Plate 1/4 Inch I SECTION V I Full Scale Tank Car Tests SECTION VX I Bare Tank Car Torch Test I SECTION VII Thermocougle Layout Full Scale Torch Test - THERMO-LAG Coated Car I SECTION IX I Results of JAN Cycle Testing on 1/5 Model Tanks Coated with THERMO-LAG
DEPARTMENT OF -TRANSPORTATION FEDERAL RAILROAD ADMINISTRATION WASHlNGTQN, O.C. 20590 JUN 2 y >9yp Or. Rubin Feldman President, TSI Inc.
3260 Brannon Avenue St..Louis, Missouri . 63239.
Dear Or. Feldman:
As per your telephone request on June 16, 1977, I am enclosing copies of fire data generated on test plates equipped with your material. The data included are:
a) A comparison of insulated tests with and without coating.
Also,a 1/8" TSI coated plate subjected to a fire hose.
b) Simulated Pool Fire'est on TSI coated plate - 1/8" inch.
c) Simulated Pool Fire Test on TSI coated plate - 3/6" inch.
d) Simulated Pool Fire Test on TSI coated plate - l/4" inch.
If you have, any questions concerning this data, please feeI free to contact me.
S ince rely, on Levi e Chic f, Ra i 1 Vehi c le Sa fety Research Division Enclosure
SECTION I COMPARISON OF .INSULATED TESTS WITH AND WITHOUT THERMO-LAG (C-2 COATING) 1/8 INCH THICK FIRE HOSE WATER TEST
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37. 8 THERHOl:OUPLE LAYOUT HalCu~ctay~', + 'Thceyvsgg.y~p)cg
SECTION VIII FULL SCALE"TORCH TEST THERMO-LAG COATED CAR
I TORCH TEST ON TSl-COBTED CRR- 2K BUG t97E WHY YEQTKBL RN tr THNNCOOPLES Pl z BHH 0 Pl z 33 GHH Pl 3S'S 39 38
TORCH TEST DN TSI-CDHTED CRR- 2K RUE !976 rt6v @moot. ma or mamcuuptxs 2B lK'8 ZK 38 T lNE CN lN 0
TORCH TEST ON TSt-COBTED CHR: 2% RUE t97E SCCNO ltEQTLCK BGH Qf'HEQNQlOH.ES
TORCH TEST ON TSt-COBTEO CRR: K'UE l976 THlRO VEQTKH. RR fF THNNGNKES
TORCH TE'ST ON TSl-COHTED CBR: K'UE )976 FllURTH lENTLGL RN QF THERNCGUKKS Pl
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TORCH TEST ON TSl-CORTED CRR- 2K RUE t976 5!XIH TERTKBL KR fF THERtlQGmpLES Pl z-888 '0 Pl z Zl EHH Pl n lQ 2S'R q 288 18 lK 28 2K 38 TtNE CNtN>
TORCH TE'ST ON TSI-CQBTEO CBR: 2K'UG l97E mp HQN QP THEHNlKDUpLEs lHH Dl
I TORCH TE5T ON T5l-CORTEP CRR: 2K RUE l976 5CG1N RGQ GF'tKB5QCOUFLES
TORCH TE5T DN TSl-CORTED CRR- 25 RUE IB7E NlDDK RN OF'KRNCDUFLCS
TORCH'EST GN TSt-COBTEI> CHR- 2K RLIE 1976 l HHH RlUBTH 80Q OP THERNNDUKE5 2Z 23 2L 2S'H I K'H 2K'5 3K'H lK'
TORCH TEST ON TSI-COBTED CRR- 2K BUb IB7f-SGTTQN.EN GF', TffRCGNJKES
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~~SECTION IX RESULTS OF JAN CYCLE TESTING ON 1/5 MODEL'ANKS COATED WITH THERMO-LAG~~
~~~ ~ 1 ~ ~ 1I ~gg ~~~
~~0 EPA RTMENT OF TRA N SPORTATION FEDERAL RAILROAD ADMINI5TRATION WASHINGTON, D.C. 20590~~
~~~ t ~ glq g ~~~
~~FE8 9 1971 Dr. Rubin Feldman. President, TSI-Inc. 3260 Brannon Avenue St. Louis, Msssourr~~
~~Dear Dr. Feldman:~~
~~Subject:~~
~~Results of JAN Cycle Testing on 1/5 Model Tanks~~
~~-This is in response to your inquiry on the status of the environmental tests conducted on three (3}', one-fifth,.scale tanks, equipped with TSI thermo-lag material.~~
The test tanks were positioned in the conditioning-oven on December 15, 1976, and were withdra'wn on January 12; 1977. The tanks were cycled in accordance with the temperature profile indicated in Enclosure
~~1. The JAN cycle temperatures were modified to include temperatures of~~
-40'F to +140'F, since these represent the normal temperature extremes encountered in land transportation. The unmodified JAN cycle is normally run between -65'F to +165'F, for fourteen days (14}, (Figure 2}.
However, two modified JAN cycle tests were run instead of one (28 days instead of 14 days}. Attachment 2, is the test report which I received' fro'm the Army Ballistics Research Laboratory. Aside. from a slight softening of the coating at elevated temperatures, no deleterious effects of the environmental treatment was found. I will forward pictures of the test tanks to you when they become available to me. Please let me know if you have any additional, questions concerning this . test. Sincerely,
~~. I 'Don Levine Chief, Rail Vehicle Safety Research Division~~
DEPARTt1FNT OF THE ARMYht> Baicy/m<<~,/; 01 U. s.'R4IY .nAL'STic REscARcH LAoof2ATQRIEs 278 ABEROEEN PROVING,CROUNO, MARYLAND 21005 DRXBR-9i~af 19 January 1977 r Depirtmcnt of Transportation Federal Railroad Administration ATTN: her. Don Levine Program h1anager Second and V Streets, SW Washington, D.C. 20590
~~Dear hir. Levine:~~
Three .1/5 scale tanks which had been spray coated with 200 mils of Thermolag .and left to weather for two years at the Transportation Test Center, Pueblo, Colorado were shipped to the Aberdeen Provinp-Ground for JAN Cycle t'esting. Since the tanks had never had a top coat applied, a thin top coat was brushed on and allowed to dry. prior to testing. JAN cycle testing began at 0800 15 December 1976. Thd JAN Environmental.Cycle was conducted in the Mortar and Recoilless Rifle Con'ditioning Unit, SP 23. The unit has a test chamber 7 feet wide, 13 foot long and 8 feet, 6 inches high in which temperature and humidity can be simulated. Temperature and humidity were controlled and recorded by two Ilone~iell htodel D8212318001 instr<<ments. Air velocity was sufficient to maintain a temperature gradient of + 2 F throughout the chamber after temperature stability was achieved. The SP 23 condi.tionin'g chamber is designed without a floor so that it can be positioned over an emplaced weapon for conditioning. For this test the floor area was covered with 1 inch thick plywood . which was covered with 4,inch thick fiberglass insulation and a
DR%BR-IA4 polycthylcnc plastic moisture barrier. After the floor-was prcparcd, two 6 hy 6 inch wooden beams werc placed acoss thc width of thc'chamhcr and the three spray coated tanks spotted on thc beams.
~~'h The test was conducted in accordance with Test 105 of MIL-STD-331 (JAN Temperature and llumidity Cycle) Figurc 1. o The cvclc 0~~
was modified so that thc temperature extrcmcs were -40 F (-65 F specified) and 140 F (160 F specified) as shown in Figuic 2. After 28 days on January 12, 1977 the testing was terminated and thc tanks removed from thc chamber. 'i'hc sprayed coatings 'remained intact on all thrcc of thc tanks and showed little change in appearance as verified by the attached photographs. Checks made during the testing indicated that some softening of thc top coat occurred at thc high tcnperatur<< (140 F) high humidity (95'.) cnd of the cycle. Attention should be called to the fact that. this is an unusually severe test and that these conditions would never be experienced in ordinary operating conditions. The Army uses this type of test only on fuzes and munitions where a problem of chemical stability and resultant safety are of concern. Sincerely yours, 2 Incls E. 0. BAICY as Program Manager Tank Car Project'
I I I
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FIGljRI: .'
PRELIMINARY ACCIDENT REPORT TANK CAR DERAILMENT JOAQUIN, TEXAS, SEPTEMBER 8, 1979 PREPARED BY: TSI, INC. OCTOBER, 1979 TSI, INC. ~ 3260 BRANNON AVE. ~ ST. LOUIS, hhO. 63139 ~ (314) 352-8422 ~ Telex:.44-2384
I I I I I
ABSTRACT On September 8, 1979, two TSI THERMO<<LAG 330 coated (fire and impact protected) tank cars, loaded with butadiene, were involved in a major derailment and subsequent fire near Joaquin, Texas. Twenty-six I (26) tank cars reportedly burned and/or exploded. The two tank cars which were fire and impact protected with THERMO-LAG 330 Subliming Coating System performed as expected - protecting the tank car and its lading from the firing inferno. More details and photographs as obtained from the "on the scene" reporters follow. The thickness of the THERMO<<LAG 330 Fire Resistive Coating applied to the two tank cars was circa 0.165 inches dry. THERMO-LAG was approved for fire resistant enhancement of tank cars by the Department of Transportation as a result of an extensive fire protection, physical, environmental and 'life cycle test program conducted by the Department of Transporta" tion, U. S. Army Ballistics Research Laboratories-Aberdeen Proving Ground, and the American Railroad Association. THERMO-LAG 330 Fire ResistiveCoating System is specifically listed in and specified by Federal Regulation HM144 for that use. The THERMO-LAG thermal protective coatings have enjoyed. an unparalleled success in many aerospace programs on such prestigious sytems as the X-15, Polaris, Saturn, etc., since the 1950's, and for commercial applications since the 1960's.
ACCIDENT SYNOPSIS "33 cars of a Southern Pacific Freight. derailed ~ near Joaquin Saturday and burst into SPECTACULAR FLAMES, spewing dangerous fumes and hugejclouds of smoke while TRIGGERING PERIODIC EXPLOSIONS.
~~"It was a nightmare come true,"'aid one resident of a nearby house who ran through fire to escape.~~
It took almost 36 hours for the 'fire to "burn itself out" enough for repair crews to move in and even at noon Monday several small columns of fire and smoke continued to rise from the wreckage."> Unofficial and preliminary National Transportation Safety Board estimates put the damage to the cars and their contents at more than 2 million dollars.2 "Explosive and toxic chemicals were in 30 loaded cars involved in the derailment, including such hazardous materials as butadiene, isobutylene, tetrahydrafuran, hydrofluoric acid, ethylene oxide, vinyl acetate, methanol, ethyl acrylate, rubber, acetaldehyde, propylene glycol (antifreeze), paint and plastics.'hree of the wrecked cars were empty. RAIL OFFICIALS SAID 26 OF THE CARS BURNED, WITH SEVERAL OF THEM EXPLODING'"1 The National Transportation, Safety Board's preliminary investigation results confirm the above-.>
I I
"Concern over a slow leak in the "HF" (hydrofluoric acid) car and possible explosion of a butadiene car was one of the main delays in reopening the highway and beginning the cleanup operations. "If it hadda gone, everything. within a mile of here woulda been levelled," said a Texas Railroad Commission safety official on the scene.
After seveal aerial inspections via helicopter of the wreckage, officials finally got up the nerve to don artificial breathing devices and make a ground inspection of the cars on ll a.m. Monday. They reported back that temperature and pressure within the "HF" car and the butadiene car appeared to be okay, MUCH TO EVERYONE'S RELIEF, even though some flames persisted in the wrecked cars around them."1 The butadiene loaded tank car in question was a Shell Car, Number SCMX 3646. It was coated in accord with Federal Regulation HM144 prerequisites with THERMO-LAG 330 Subliming Coating System in September 1978. Initial investigation indicates that it was exposed to simultaneous torching and fire engulfment from several cars around it. As you will note from Photograph N7, after the derailment the geographic location resembles a ravine. ,All the tank cars subject to the derailment or involved in the derailment were piled into a tight proximity to one another, literally adj'acent to each other irrespective of their initial order in which they were placed on the train. The condition of the THERMO-LAG protected tank car, as reported in the preliminary NTSB investigation was "Engulfed by fire - no product loss" 2 even though there was a 920,000 damage to the car as a result of the derailment. Photographs SPl through N6 show closeup views of the THERMO-LAG protected car after the derailment. You will note that with the exception of the replacement of the coating which had been consumed as per the design, and
the mechanical repairs which will need to be made, no other damage occurred. The tank car was properly protected from fire. There was no explosion or other failure that would have endangered life or property and the lading was essentially left intact. Photographs N8 through 13 show closeups of the wreckage. Please note that the tank cars in the wreckage, with the exception of the THERMO-LAG protected car, are beyond repair. Even though the THERMO-LAG protected tank car was subjected to many impacts, it performed as anticipated. More details on this accident will be made available very soon. We welcome your inquiries. TSI, INC. 3260 Brannon Avenue St. Louis, Missouri 63139 Phone: 314 352-8422
REFERENCES References used in the preparation of this Preliminary Accident Report are as follows: THE EAST TEXAS LIGHT, Shelby County, Texas P 0 Box 1289 Center, Texas 75935 (173) 598-3377 Wednesday, September 12, 1979 Volume 56, Number 64 TRAIN WRECK SPEWS DANGER>> By Wain Miller National Transportation Safety Board Hearing "NTSB Meeting - Joaquin, Texas Derailment September 8, 1979 Held at Houston, Texas SP Building October 3-4" 4
I I r' I I I I
PHOTOGRAPH 813 SCENE OF THE ACCIDENT TANK CAR DERAILMENT AND FIRE JOAQUIN, TEXAS SEPTEMBER 8, 1979
PHOTOGRAPH 812 SCENE OF THE ACCIDENT TANK CAR DERAILMENT AND FIRE JOAQUIN, TEXAS SEPTEMBER 8, 1979
I' vj I I P
~~)k t,'HOTOGRAPH 811 SCENE OF THE ACCIDENT TANK CAR DERAILMENT AND FIRE JOAQUIN, TEXAS SEPTEMBER 8, 1979~~
I I I I
SCENE OF THE ACCIDENT TA%C CAR DERAILMENT AND FIRE JOAQUIN, TEXAS SEPTEMBER 8, 1979
I PHOTOGRAPH 89 SCENE OF THE ACCIDENT TANK CAR DERAILMENT AND FIRE JOAQUIN, TEXAS SEPTEMBER 8, 1979
PHOTOGRAPH 88 SCENE OF THE ACCIDENT TANK CAR DERAILMENT AND FIRE JOAQUIN, TEXAS SEPTEMBER 8, 1979
PHOTOGRAPH 717 AERIAL VIEW >> WRECKAGE TANK CAR DERAILMENT JOAQUIN, TEXAS SEPTEMBER 8, l979
PHOTOGRAPH 86 THERMO-LAG PROTECTED TANK CAR AFTER 36 HOUR EXPOSURE TO FIRE JOAQUIN>> TEXAS SEPTEMBER 8, 1979
PHOTOGRAPH g5 THERMO-LAG PROTECTED TANK CAR AFTER 36 HOUR EXPOSURE TO FIRE JOAQUIN, TEXAS SEPTEMBER 8, 1979
1 PHOTOGRAPH 84 THEm-LAG PROTECTED TANK CAR AFTER 36 HOUR EXPOSURE TO FIRE JOAQUIN, TEXAS SEPTEMBER 8, 1979
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I TSI TECHNICAL NOTE 80181 THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM APPLICATION PROCEDURES 8/81 REVISION I
TSI TECHNICAL NOTE 80181 REVISION I 8/81 PREPARED BY: Wilbur 'Paddock Manager of Production REVIEWED BY: R. A. man Man r, Quality Assurance APPROVED BY: R. Feldman President
TABLE,OF CONTENTS SECTION TITLE PAGE NO.
~~1.0 INTRODUCTION~~
UNPRE-APPLICATION 2.0 =PRACTICES 3.0 FABRICATION OF STRESS SKIN ENVELOPE 4.0 COATING APPLICATION TECHNIQUES 19 5.0 TOPCOAT- APPLICATION 22 6.0 POST APPLICATION PRACTICES 22 7.0 EQUIPMENT SUGGESTIONS 23 APPENDIX A SCHEMATIC OF SUGGESTED PENETRATING MEASURING DEVICES 24 APPENDIX B SUGGESTED COMPLEMENT OF REQUIRED SPRAY EQUIPMENT FOR THERMO-LAG 330-1 SUBLIMING COATING APPLICATION 25 APPENDIX C APPLICATION PROCEDURES STRUCTURAL STEEL ENTITIES 27 APPENDIX D TYPICAL APPLICATION DETAILS APPENDIX E FIREPROOF COATING THICKNESSES REQUIRED FOR VARIOUS STRUCTURAL STEEL MEMBERS
I'sl LIST OF FIGURES FIGURE PAGE NUMBER TITLE NO. THERMO-LAG Stress Skin Type 330-69 Typical Layout for Cable Tray Sections THERMO-LAG Stress Skin Type 330-69 Installation Schematic Prior to THERMO-LAG 330-1 Subliming Coating Application 1.0.3 Cross Sectional View of THERMO-LAG 330-1 Subliming Coating Envelope System Applied to a Typical Cable Tray 1.0.4a THERMO-LAG Stress Skin Type 330-69 Installation Schematic Prior- to THERMO-LAG 330-1 Subliming Coating Application 9a 1.0.4b Installation Schematics For Attaching Additional Sections of THERMO-LAG Stress Skin Type 330-69 to Previously Installed THERMO-LAG Stress Skin Type 330-69 9b 1.0.5a Cross Sectional View of THERMO-LAG 330-1 Subliming Coating Envelope System Applied to Cable Drops 10a 1.0.5b Cross Sectional View of THERMO-LAG 330-1 Subliming Coating Envelope System Applied to Cable Drops 12a 1.0.6a Cross Sectional View of THERMO-LAG 330-1 Subliming Coating-Envelope Syst'm Applied to Conduit and Cable Drop 13a 1.0.6b Cross Sectional Vi'ew of THERMO-LAG 330-1 Subliming Coating Envelope System Applied ' to Cable Tray and Cable Drop 13b 1.0. 7 Cross Sectional View of THERMO-LAG 330-1 Subliming Coating Envelope System Applied to a Junction Box Assembly
TSI TECHNICAL NOTE 80181 THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM APPLICATION PROCEDURES
~~1.0 INTRODUCTION~~
This procedure, sets forth the sequential steps involved in applying THERMO-LAG 330-1 Subliming Coating Envelope System to cable trays, cable drops, conduit, )unction box assemblies, and structural steel. The THERMO-LAG 330-1 Subliming Envelope System consists of THERMO-LAG Stress Skin Type 330-69, THERMO-LAG 330-1 Subliming Coating, Fiberglass Armoring, and where required., THERMO-LAG 330-70 Conformable Ceramic Blanket and. THERMO-LAG 350 Two Part Spill Resistant Topcoat. 2.0 PRE-APPLICATION PRACTICES 2.1 alifications of Contractor The application shall be performed by a qualified'ontractor who has had prior training in applying the material and who has the equipment required to perform the application. 2.2 Safet Precautions The contractor shall follow standar'd industrial safety, practices established for the handling of chemical coatings and shall conform to applicable OSHA and owner safety rules in all respects. 2.3 ~Deliver The coating materials shall be delivered to the gob site in original,
~~.unopened containers which show, the'product name, batch number, color, name of the manufacturer, the expiration date, and where applicable, an Underwriters'aboratories label.~~
2.4 ~Stora e The coating materials shall be stored off the ground when'ot in use in an area provided for that purpose. The materials in storage shall be protected against freezing and from temperatures above 100'F. 2.5 Tem erature and Preci itation The coating 'materials shall be applied only to dry surfaces. The temperature of the coating material and surfaces to be coated shall be above 40'F during the material application and curing periods. The contractor shall furnish and install any protective covers required to protect the newly applied coating from rainfall or hard fieeze during its initial curing period. 2.6 Protection of Ad acent Surfac'es The contractor shall mask off or otherwise protect all adjacent areas and in place equipment from receiving any material overspray during the coating application. Any spilled material and overspray shall be removed promptly using water, wet rags or sponges before the material has dried. 3.0 FABRICATION OF STRESS SKIN ENVELOPE 3.1 Cable Tra s (Fi ures 1.0.1, 1.0.2, 6 1.0.3) 3.1.1 Cut a piece of material large enough to form the bottom section from a roll of Stress Skin. The width of the bottom section sha'll be equal to the sum of the base (W) and both sides (H) of the cable tray plus 34 inches, as shown in Figure 1.0.1 . The length of the bottom piece of material shall not exceed 10 feet since longer sections are unwieldy and are difficult to install. 3.1.2 Cut a square 14 inch piece from each corner of the bottom section of the Stress Skin. 3.1.3 Form a "U" shaped section by making two 90'ends along the dotted lines which are located at each end of the W + 4" dimension line shown in Figure 1.0.1.
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3.1.4 Form a 14" flange on each side of the'ottom section by making a 90' bend along the dotted lines as shown in Pigure 1.'O.l. 3.1.5 Cut a piece of material large enough to form the top section from a roll of Stress Skin. The width of the top section shall be equal to the'base (W) of the cable plus 24". 3.1.6 Porm a 14" flange at each end of the top section by making 90'ends along the dotted lines shown in Figure 1.0.1. 3.1.7 Drill holes for fastening the bottom and top sections together as required in the flanges of both sections as shown in Figure 1.0.2. Mount the bottom and top sections of Stress Skin on the cable tray and fasten the two sections, together at a maximum of six inch intervals using mechanical fasteners, staples or 18 ga. galvanized tie wire. 3.1.9 Attach additional 'bottom and top sections of Stress Skin to a previously installed section by fastening them together at the 'end flanges using mechanical fasteners, staples or 18 ga. galvanized tie wire. 3.1.10 Coat the bottom and top sections of Stress Skin with THERMO-LAG 330-1 Subliming Coating as shown in Figure 1.0.3. ,The coating shall be applied with Fiberglass Armoring in accordance with the instructions given in Section 4.0 of this procedure. OR WHEN COATING'PRIOR TO MOUNTING 3.1.11 Coat the bottom and top sections of Stress Skin with THERMO-LAG 330-1 Subliming Coating prior'to mounting on the cable tray. The coating shall be applied with Fiberglass Armoiing in accordance with instruc-tions given in Section 4.0 of this'procedure. 3.1.12 Drill holes for fastening the bottom and top sections together as . required in the flanges of both sections as shown in Figure 1.0.2.
I FIGURE 1.0.2 THERMO-LAG STRESS SKIN TYPE 330-69 INSTALLATION SCHEMATIC PRIOR TO THERMO-LAG 330-1 SUBLIMING COATING APPLICATION TOP SECTION HOLES FOR MOUNTING S1IFFENERS PLANGES BOTTOM SECTION 5
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FIGURE 1.0.3 CROSS SECTIONAL VIEW OF THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM APPLIED TO A TYPICAL CABLE TRAY THERMO-LAG 330-1 SUBLIMING COATING
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~~CABLE THERMO-LAG STRESS SKIN TRAY TYPE 330-69 SHELL~~
~~. CABLES~~
3.1.13 Mount the bottom and top sections of the precoated Stress Skin on the cable tray and fasten the two sections together at a maximum of six inch intervals using mechanical fasteners, staples or 18 ga. galvanized tie wire. 3.1.14 .'Attach additional precoated bottom and top sections of Stress Skin to a previously installed section by fastening them together at the end flanges using mechanical fasteners, staples or 18 ga. galvanized tie wire. 3.1.15 Apply a coating of THERMO-LAG 330-1 Subliming Coating in the specified wet film'hickness to the edges and joints of the precoated sections of Stress Skin using a trowel or stiff bristle brush to or fastening holes. fill in any gaps 3.2 Conduit (Fi re 1.0.4 3.2.1 Cut two pieces of Stress Skin large enough to form a top and a bottom section for the conduit. The width of each piece shall be equal to 4", of the circumference of the conduit plus 1". The length of the
~~'piece of Stress Skin shall not exceed 10 feet since longer sections are unwieldy and more difficult to install.~~
3.2.2 Form a semi-circular section with edge flanges from each of the two pieces by making two 90'ends at a distance of 1/2 inches from each edge of the width dimensions as shown in Figure 1.0.4a. For sharp radius bends, the procedure delineated in Section 3.0 for the fabrication of Stress Skin Envelope utilizing, a design as shown in Figure 1.0.2 shall apply for conduit when sharp radius bends must be coated. 3.2.3 Form a 4" flange on the length edges of each of the two pieces, where required, by making 90'ends. 3.2.4 Drill holes for fastening the bottom and top sections together at a maximum of six inch intervals in the flanges of both sections when required. 3.2.5 Mount the bottom and top sections of Stress Skin on the conduit and fasten the two sections together at a maximum of six inch intervals using mechanical fasteners, staples or 18 ga. galvanized tie wire.
3.2.6 Attach additional bottom and top sections of Stress Skin to a previously installe'd bottom snd top sections as shown in Figure 1.0.4b. a) Overlapping the'bottom and top sections by a maximum of or b) Pastening them together at the end flanges using mechanical fasteners,'taples or 18. ga. galvanized tie wire. 3.2.7 Coat the bottom and top sections of Stress Skin with THERMO-LAG 330-1 Subliming Coating The coating shall be applied with Piberglass Armoring in accordance with instructions given in Section 4.0 of this procedure. OR WHEN COATING PRIOR TO H)UNTING 3.2.8 Coat the bottom and top sections of Stress Skin with THERMO-LAG 330-1 Subliming Coating prior to mounting on the conduit. The coating shall be applied with Piberglass Armoring in accordance with instruc-tions given in Section 4.0 of this procedure. 3.2.9 Drill holes for. fastening the bottom and top sections together as required in the .flanges of both sections. 3.2.10 Mount the bottom and tops secti'ons of the precoated Stress Skin on the conduit and fasten the two sections together at a maximum of six inch intervals using mechanical fasteners, staples or 18 ga. galvanized tie wire. 3.2.11 Attach additional precoated bottom and top sections of Stress Skin to a previously installed section by fastening them together at the end flanges using mechanical fasteners, staples or 18 ga. galvanized tie wire as shown in Pigure 1.0.4b. 3.2.12 Apply a coating of 'GKBHO-LAG 330-1 Subltudng Coating in the specified wet film thickness to the edges and points of the precoated sections of Stress Skin using a .trowel or stiff bristle brush to gapa or fastening holes. fill in .any
I FIGURE 1.0.4a THERMO-LAG STRESS SKIN TYPE 330-69 INSTALLATION SCHEMATIC PRIOR TO THERMO-LAG 330-1 SUBLIMING COATING APPLICATION . THERMO-LAG Stress Skin Type 330-69
~~/ Conduit /I N~ ~~~~
9a
FIGURE 1.0.4b INSTALLATION SCHEMATICS FOR ATTACHING ADDITIONAL SECTIONS OF THERMO-LAG STRESS SKIN TIVE 330-69 TO PREVIOUSLY INSTALLED THERMO-LAG STRESS SKIN TYPE 330&9 THERMO-LAG STRESS SKIN END FLANGES END FLANGES THERMO-LAG STRESS SKIN CONDUIT THERMO-LAG STRESS SKIN 2" M1nimum Overlap THERMO-LAG STRESS SKIN CONDUIT 9b
'I 3.3 Cable.Dro s (Fi ure 1.0.5 ) 3.3.1 Cut a piece of Stress Skin large enough to wrap around the circum-
,ference of a single or multiple number of cable drops. The width of the piece should be equal to the circumference of the single or group of cable drops plus an additional 3/4" minimum to provide for the overlap. The length of the piece of material shall not exceed 10 feet since longer sections are unwieldy and more difficut to handle.
3.3.2 Wrap the piece of Stress Skin around the single or group of cable drops and secure at a maximum of six inch intervals with 18 -ga. galvanized tie wire. Attach additional pieces of Stress Skin to a previously wrapped piece by overlapping by a minimum of six inches and secure with 18 ga. galvanized tie wire. 3.3.3 Cut a piece of THERMO-LAG 330-, 70 Conformable Ceramic Blanket large enough to wrap around the circumference of the installed Stress Skin. The width of the'piece should be equal to the circumference of the installed Stress Skin plus Q" minimum to provide for a tight abutment of the edges. The length of the piece of material shall not exceed 10 feet in order to minimize the handling problems during installation. 3.3.4 Wrap the piece o'f Conformable Ceramic Blanket around the installed piece of Stress Skin and secure at a maximum of six inch intervals with 18 ga. galvanized tie wire. Attach additional pieces as required of the Conformable Ceramic Blanket to a previously installed piece by tightly abutting the pieces together. Care should be exercised to ensure that the wrapping of the Conformable Ceramic Blanket is continuous with no gaps or holes in the material surfaces. 3.3.5 Cut two pieces of Stress Skin large enough to form a top and a bottom section. The width of each piece shall be equal to one half of the circumference of the installed Conformable Ceramic Blanket plus 2Q" minimum. The length of the piece of material shall not exceed 10 feet since longer sections are unwieldy and more difficult to handle. 3.3.6 Form a semi-circular section with edge flanges from each of the top pieces by making two 90'ends at a distance of lg" minimum from each edge of the width dimension. 10
'I FIGURE I.O,5~ CROSS SECTIONAL VIEW OF THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM APPLIED TO CABLE DROPS THERMO-LAG 330-1 FIBERGLASS 'ARMORING THERMO-LAG 330-1 l ~WE r TEERNO-LAG STRESS SKIN
~~-r r CONFORMABLE CERAMIC BLANKET FASTENER THERMO"LAG STRESS SKIN TIE WIRE TIE WIRE~~
3.3.7 Form a 14" flange on the length edges of each of the two pieces, when required, by making 90'ends. 3.3.8 Cut holes for fastening the bottom and top sections together at a maximum of six inch intervals in the flanges of both sections. 3.3.9 Mount the bottom and top sections. of Stress Skin on the Conformable Ceramic Blanket and fasten the two sections together at a maximum of six inch intervals using mechanical fasteners, stapes or 18 ga. galvanized tie wire. 3.3.10 Attach additional bottom and top sections of Stress Skin to a previously installed bottom and top section by fastening them together at the end flanges using mechanical fasteners, staples or 18 ga. galvanized tie wire. 3.3.11 Coat the bottom and top sections of Stress Skin with 'QiERMO-LAG 330-1 Subliming Coating as shown in Figure 1.0.5a. The coating shall be applied with Fiberglass Armoring in accordance with the instructions given in Section 4.0 of this procedure.
.3.3.12 Cable Drops (Fi ure 1.0.5b) 3.3.12.1 Cut a piece of Stress Skin large enough to wrap around the circum-ference of a single or multiple number of cables. The width of the piece should be equal to the circumference of the single or group of cable drops plus an additional 3/4" minimum to provide for the overlap. The length of the piece shall not exceed 10 feet since longer sections are unwieldy and more difficult to handle.
3.3.12.2 Wrap the piece of Stress Skin around the single or group of cable drops and secure at a maximum of six inch intervals with 18 ga. galvanized tie wire. Attach additional pieces of Stress Skin to a previously wrapped piece by overlapping by a minimum of six inches and secure with 18 ga. galvanized tie wire.
3.3.12.3 Coat the section of Stress Skin with THERMO-LAG 330-1 Subliming Coating as shown in Figure 1.0.5b. The coating shall be applied with Fiberglass Armoring in accordance with instructions given in Section 4.0 of, this procedure. 3.3.12.4 Cut a piece of 'THERMO-LAG 330-70 Conformable Ceramic Blanket large enough to wrap around the circumference of the installed Stress Skin. The width of the piece should be equal to the circumference of the installed Stress Skin plus g" minimum to provide for a tight abutment of the edges. The length of the piece of material shall not exce'ed 10 feet in order to minimize the handling problems during installation. 3.3.12.5 ~ Nrap the piece of Conformable Ceramic Blanket. around the installed piece of Stress Skin and secure at a maximum of six inch intervals with 18 ga. galvanized tie wire. Attach additional pieces as required of the Conformable Ceramic Blanket to a previously'nstalled piece by tightly abutting the pieces together. Care should be exercised to ensure that the wrapping of the Conformable Ceramic Blanket is continuous with no gaps or holes in the material surfaces. 3.3.12.6 Cut two pieces of Stress Skin large enough to form a'top and a bottom section. The width of each piece shall be equal to one half of the circumference of the installed Conformable Ceramic Blanket plus 2g" minimum. The length of the piece of material shall not exceed 10 feet since longer sections are unwieldy and more difficult to handle. 3.3.12.7 Form a semi-circular section with edge flanges from each of the top pieces by making two 90'ends at a distance of lg" minimum from each edge of the width dimension. 12
FIGURE 1.0.5b CROSS SECTIONAL VIEW OF THERMO-LAG 330>>1 SUBLIMING COATING ENVELOPE SYSTEM APPLIED TO CABLE DROPS THERMO-LAG 330-1 FIBERGLASS ARMORING THERMO.'-LAG 330-1 l
~~< S THERMO-LAG STRESS SKIN r r i~~~
CONFORMABLE CERAMIC BLANKET J r C THERMO-LAG 330-1 FASTENER THERMO-LAG STRESS SKIN TIE WIRE TIE WIRE 12a
I I
3.3.12.8 Form a 14" flange on the length edges of each of the two pieces, when required, by making 90'ends. 3 3.12-9 'ut holesof'ix maximum for fastening the bottom and top sections together. at a inch intervals in the flanges of both sections. 3 '.12 10 'Mount the bottom and top sections of,'Stress Skin on the Conformable, Ceramic Blanket and fasten the two sections together at a maximum of six inch intervals using mechanical fasteners, stapes or 18 ga. galvanized tie wire. 3.3.12.11 Attach additional bottom and top sections of Stress Skin to a previously installed bottom and top section by fastening them together at the end flanges using mechanical fasteners, staples or 18 ga. galvanized tie wire. 3.3.12.12 Coat the bottom and top sections of Stress Skin with THERMO-LAG 330-1 Subliming Coating as shown in Figure 1.0.5b. The coating shall be applied with Fiberglass Armoring in accordance with the instructions given in Section 4.0 of this procedure. 3.4 Conduit and Cable Dro Junction (Fi ure 1.0.6) 3.4.1 Apply the THERMO-LAG 330-1 Subliming Coating Envelope System to the conduit and the single or multiple cable drops following the instructions'given in Section 3.2 or 3.3 of this procedure. 3.4.2 Cut a piece of Stress Skin of sufficient size to wrap around the circumference of the conduit. The width of the piece should be equal to the outside circumference of the conduit plus an additional 3/4 inch to provide for an overlap. The length of the piece shall be 12 inches minimum. 3.4.3 Wrap the piece, of Stress Skin around the outside circumference of the conduit in such a manner that it. covers six inches of the conduit. Secure the piece of .'Stress Skin to the conduit with'two 18 ga. gal-vanized tie wires mounted approximately 5 inches apart. 13
FIGURE 1.0.6a CROSS SECTIONAL VIEW OF THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM APPLIED TO CONDUIT .AND CABLE DROP CONDUIT THERMO-LAG 330-1 5r BEVELED EDGE OF . C THERMO-LAG STRESS SKIN THERMO-LAG 330-1 FIBERGLASS ARMORING AND FIBERGLASS ARMORING FIBERGLASS ARMORING THERMO-LAG'STRESS~SKI r THERMO-LAG 330-1 THERMO-LAG STRESS SKIN CABLE DROP~ 13a
I 3.4.4 Cut a required number of small pieces of THERMO-LAG 330-70 Conformable Ceramic Blanket from a roll of this material. 3.4.5 Insert the small pieces of Conformable Ceramic Blanket inside the open end of the installed piece of Stress Skin and around and between the cable drops in such a manner that the open end is relatively sealed. Then secure the. piece of Stress Skin to the cable drops with 18 ga. galvanized tie wires. 3.4.6 Coat the installed piece of Stress Skin with THERMO-LAG 330-1 Subliming Coating as shown in Figure 1.0.6. The coating shall be applied with Fiberglass Armoring in accordance with the instruc-tions given in Section 4.0 of this procedure. 3.5 Cable Tra and Cable.Dro Junction at 0 en End of Cable Tra 3.5.1 Apply the THERMO-'LAG 330-1 Subliming Coating Envelope System to the cable tray at the single or mu1tiple cable drops following the instructions given in Sections 3-1 and.3.3 'of this procedure.
~~'.5.~~
2 Cut a piece of Stress Skin of sufficient size to wrap around the outside parameters of the cable tray. The width of the piece should be equal to the outside parameter of the cable tray plus an additional 3/4" 'to provide for .an overlap. The length of the piece shall be 24 inches minimum. 3.5.3 Wrap the piece of Stress Skin around the parameter of the cable tray in such a manner that it covers six inches of, the conduit. Secure the piece of Stress Skin to the conduit with two 18 ga. galvanized tie wires mounted approximately 5 inches apart. 3.5.4 Cut a required number of small pieces of the THERMO-LAG 330-70 Conformable Ceramic Blanket from a roll of this material. 3.5.5 Cut slots approximately 12 inches in length at each corner of the open end of the piece of Stress Skin. 14
FIGURE 1.0.6b CROSS SECTIONAL VIEW OF THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM APPLIED TO CABLE TRAY AND CABLE DROP GABLE TRAY BEVELED EDGE OF THERMO-LAG 330-1 AND FIBERGLASS ARMORING THERMO-LAG 330-1
~~~MAO-LAC STRESS IN FIBERGLASS ARMCRBiG FIBERGLASS ARggRIN~G IRRRMOLISG S-IRRSS~SKI r~~
THERMO-LAG 330-) THERMO-LAG STRESS SKIÃ SABIR DROP~
3.5.6 Insert the small pieces of Conformable Ceramic Blanket inside the installed piece of Stress Skin and around and between the cable drops in such a manner that when the slit open end of the piece of Stress Skin is tightened around the cable drops, the open end is effectively sealed. Then secure the piece of Stress Skin to the cable drops with 18 ga. galvanized tie wires. 3.5.7 Coat the installed piece of Stress Skin with THERMO-LAG 330-1 Subliming Coating in the required thickness. The coating shall be applied with Fiberglass Armoring in accordance with the instructions given in Section 4.0 of this procedure. 3.6 Cable Tra and Cable Dro Junction at To or Bottom of Cable Tra 3.6.1 Apply the THERMO-LAG 330-1 Subliming Coating Envelope System to the cable tray and the single or 'multiple cable drops following the instructions given in Section 3.1 and 3.3. 3.6.2 Cut a piece of Stress Skin of sufficient size to form a truncated cone shape which has one end that is equal to the circumference of the cable drops plus 3/4 inch to provide for overlaps. The other end should be approximately four times the circumference of the cable drops plus 3/4 inch to provide. for overlaps. The length of the piece should be 6 inches minimum. 3.6.3 Form a 1" flange at the large end of the piece of Stress Skin by making a 90'end along a line which is*1" up and parallel to the large end. Drill holes for fastening the flange to the cable tray as required in the flange. 3.6.4 Cut a required number of small pieces of THERMO-LAG 330-70 Conformable Ceramic Blanket from a roll of this material. 3.6.5 Form a cone out of the piece of Stress Skin taking care to overlap the sides by 3/4 inch. 15
I I I I I
3.6.6 Insert the small pieces of Conformable Ceramic Blanket inside .the small end of the cone in such a manner that the small end is sealed when it is wrapped around the cable drops. Then secure the small end of the piece of Stress Skin to the cable drops with 18 ga. galvanized tie wires. 3.6.7 Secure the flanged end of the piece of Stress Skin to the cable tray using mechanical fasteners, staples or 18 ga. galvanized tie wires. 3.6.8 Coat the install'ed piece of Stress Skin with THERMO-LAG 330-1 Subliming Coating. The coating shall be applied with Fiberglass Armoring in accordance with the instructions given in Section 4.0 of this procedure. 3.7 Cable Tra or Conduit Junction With Pire Wall
~~3. 7.1 Attach the Stress Skin Envelope of the cable tray or conduit at each junction with a fire wall by fastening the butt flange of the Stress Skin to the fire wall using mechanical fasteners.~~
3.7.2 Apply the THERMO-LAG 330-1 Subliming Coating to the butt flanges, overlapping the flange joints with the coating by a minimum of 3 inches. The coating shall be applied with Fiberglass Armoring in accordance with the instructions given in Section 4.0 of this procedure. 3.8 Junction Box Assembl (Pi ure 1.0.7 3.8.1 Cut two pieces of Stress Skin large enough to form the top and bottom sections of the main assembly section of, the junction box assembly as shown in Figure 1.0.7. The width of each piece of material shall be equal to the width of the junction box plus 5 inches and the length of each piece shall be equal to the depth of the junction box plus 3 inches. The additional 5 inches provides for 14" flanges and 14" clearance from the side. edges of the junction box. The "additional 3 inches provides for 14" flanges and lg" clearance along the sides of the junction box. 16
FIGURE 1.0.7 CROSS SECTIONAL VIEW OF THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM APPLIED TO A JUNCTION BOX ASSEMBLY CONDUIT COVERED WITH THERMO-LAG STRESS SKIN, THERMO-LAG 330-1 AND THERMO-LAG FIBERGLASS ARMORING 330-1 SUBLIMING COATING
~~+i" THERMO-LAG 330-1 AND FIBERGLASS ARMORING D~~
~~MAIN ASSEMBLY THERMO-LAG 330-1 SECTION APPLIED TO THERMO-LAG STRESS SKIN FRONT PLATE SECTION re~~
~~~ t THERMO-LAG FASTENERS~~
~~0 'T SKIN 17~~
3.8.2 Cut any required holes for cable drops in the top and bottom sections. 3.8.3 Form a 1V'lange on each of the four sides-of the top and bottom section of Stress Skin by making the required number of 90'ends. 3.8.4 .Drill holes for fastening the top and bottom sections at a maximum of 6 inch intervals in the flanges as shown in Figure 1.0.7. 3.8.5 Cut two pieces'f Stress Skin large enough to form the two side sections of the main assembly section. The width of each piece of Stress Skin shall be equal to the height of the junction 'box plus 5 inches and the length of each piece. shall be equal,to the depth of the )unction box 'plus 3 inches. The additional 5 inches provides for 14" flanges and 14" clearance from the top and bottom edges of the junction box. The additional 3 inches provides for 14" flanges and V'learance along the sides of the )unction box. 3.8.6 Drill any required holes for cable drops in the two side sections. 3.8.7 Form a 14" flange on each of the four sides of the two side sections of Stress Skin by making the required number of 90'ends. 3.8.8 Drill holes for fastening the two side sections at a.maximum of 6 inch intervals in the flanges as shown in Figure 1.0.7. , 3.8.9 Cut a piece of Stress Skin large enough to form the front plate section. The width of the front plate section shall be equal to the width of the top and bottom sections plus 24" required to cover t'e flanges. The length of the front plate section shall be equal to 'the height of the side sections plus 24" required to cover the flanges. 3.8.10 Drill holes for fastening the front plate section to the main assembly . section as shown in Figure 1.0.7. 3.8.11 Mount the main assembly section around. the junction box by connecting the top. and bottom sections to the two side sections and attaching the main assembly section to the wall on which the )unction box is mounted using mechanical fasteners, staples or 18 ga. galvanized tie wires. 18
I 3.8.12 Mount the front plate section on the main assembly section using mechanical fasteners, staples or 18 ga. galvanized tie wire. 3.8.13 Coat the assembled front plate 'and main assembly sections of Stress Skin with THERMO-LAG 330-1 Subliming Coating. The coating shall be applied with Fiberglass Armoring in accordance with the instructions given in Section 4.0 of this procedure. 3.9 , Structural Steel Su orts 3.9.1 See Appendix C of this procedure for application instructions. 4.0 COATING APPLICATION TECHNI UES. 4.1 S ra A lication 4.1.1 Apply the THERMO-LAG 330-1 Subliming Coating over a properly prepared surface. Make sure that the surface to be coated is clean, dry, above 40'F and free from scale, rust or'other contaminants. 4.3..2 'pply the material in as many passes as required to provide the, required film build of coating thickness, taking care to avoid slumping or sagging of the coating. Normally, a required 0.500 inch dry coating thickness is accomplished by applying three wet coats of 0.225 inches. However, the thickness which can be safely applied in a single pass will depend on the temperature, humidity, and other factors that are best determined on the job site. 4.1.3 Apply the material in smooth even passes, taking care to keep the spray gun fan pattern at a 90'ngle whenever possible. Reaching with a spray gun will cause the spray pattern to vary from the 90'ngle and will result in a rougher surface than normal. 4.1.4 Take frequent wet thickness measurements during the application using a penetration measuring device such as those shown in Appendix A to ensure that the coating is being applied uniformly and at the, required wet film thickness. These wet thickness checks shall b'e made every five square feet or every two running feet of coated surface area. (Note: When taking measurements allow for a shrinkage rate of 25% between the wet and the desired dry film coating .thickness. 19
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4.1.5 Remove excess build up of coating material at edges and points by brushing or rolling the surface with a damp sponge roller. 4.1.6 Spray edges of the substrate from each side to cause the material to wrap around the edge. If the edge coating is not'completely closed, use a wet roller or trowel to seal the edge surface. 4.1.7 Apply Piberglass Armoring to the wet surface after the final pass and use a roller to flatten out any wrinkles and to embed the fiberglass securely. Then apply sufficient material. to cover the embedded fiberglass. 4.1.8 Remove all runs, sags, drips or other surface imperfections before the material cures using wet sponge rollers, brushes or hand trowels. 4.2 Hand A lications 4.2.1 Trowel the material to a uniform thickness using moderate pressure and avoid overworking the material. The trowel should be wetted with water when a smooth finish is required. 4;2.2 Glove the material to cables and small pipe using standard work gloves. Work small areas and keep the gloves wet to insure a . relatively uniform thickness. ,4.3 D Pilm Thickness Measurements . 4.3.1 Take dry film thickness measurements after the applied material has cured. Measurements shall be made using electrical, penetrating or magnetic measuring instruments. 20
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4' Re air Procedure Dama e 4.4.1 Remove damaged and loose material using a knife and scrapper. Cut back until sound adhering material is reached. 4.4.2 The edge should be undercut to form a beveled edge as in plaster repair. 4.4.3 Remove all foreign matter from the substrate using a wire brush. 4.4 ' Spray or 'trowel THERMO-LAG 330-1 onto patch area. Several coat of the material can be applied to achieve the desired film thickness. Be sure to allow for shrinkage of repair patch by building up a slight dome shape with the patch. 4.5 Cable Re lacement - Re air sections by cutting material at the side butt flanges.
~~'4.5.1 Remove away and 4.5.2 Remove fasteners from flanges and carefully remove coated sections.~~
4.5.3 After work is completed, reattach envelope system using mechanical fasteners, staples or 18 ga. galvanized tie wires. 4.5.4 Apply a coating of THERMO-LAG 330-1 Subliming Coating in the specified wet thickness to the edges and joints of the reinstalled sections using a trowel or stiff bristle brush to fill in any uncoated areas. 21
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5.0 TOPCOAT APPLICATION 5.1 S ra A lication 5.1.1 Pour Part B into Part A and thoroughly mix using a. mechanical mixer. Mix a minimum of 5 minutes and allow a "sweat in" period'of 20 minutes before commencing the application. ~ i 5.1.2 Insure that the area to be topcoated is free from loose and foreign, matter. 5.1.3 Take moisture meter readings of the applied subliming coated surface using a Delmhorst Moisture Meter (Model DP) or equivalent. Obtain a reading of 20 or less before applying the topcoat. 5.1.4 Place mixed material into spray rig. 5.1.5 Apply topcoat in a smooth even pattern, making sure to criss-cross the area in a continuous film. 5.2 Hand A lication 5.2.1 Apply a full smooth coat of topcoating using a long nap mohair roller. Avoid excessive buildup of topcoat in corners and always work to a wet edge of applied topcoat. 6.0 POST APPLICATION PRACTICES 6.1 A clean and orderly condition shall be maintained in the application area. Following the application, all overspray, debris and equipment
~~,shall be removed and the area left in a condition acceptable to the owner.~~
22
I 7.0 E UIPMENT SUGGESTIONS 7.1 The most economical and satisfactory method of applying THERMO-LAG 330-1 Subliming Coating is by either airles or air type spray equipment. 7.1.1 Air type spray equipment is recomm'ended for use in spraying cable drops and conduit in order to minimize overspray. 7.1.2 Airless spray equipment is recommended for use in spraying larger sections such as cable trays and large I beams. 7.1.3 Suggested complement of spray equipment for both types are shown in Appendix B. 23
'I APPENDIX A SCHEMATIC OF SUGGESTED PENETRATING MEASURING DEVICES h "A" is equal to the desired thickness of the coating. On measurement the pin portion of the gauge must sink completely into the layer of the applied coating. Take several readings for each thickness. Fill the hole created by the gauge after measurement is completed. 24
APPENDIX B SUGGESTED COMPLEMENT OF REQUIRED SPRAY EQUIPMENT FOR THERMO-LAG 330-'1'UBLIMING COATING APPLICATION AIRLESS SPRAY EQUIPMENT UANTITY DESCRIPTION OF E UIPMENT 1 Each Hydra Spray Pump 45:1 1 Each Air Powered Ram 1 Each Hydra Mastic Spray Gun 1 Each Special Dump. Valve 2 Each RAC III with 0.55 Tips 1 Each Air Agitator 1 Each Air Regulator Kit 1 Each Air Regulator Only with Gauge 1 Each Air Line Filter 1 Each Air Line Lubricator 5 Each Pump Repair Parts Kits 6 Each , Extra Tips with Seals 100= Feet 1 Inch I.D. Hi Pressure Fluid Hose 75 Feet 1/2 Inch I.D: Hi Pressure Fluid Hose 25 Feet 3/8 Inch I.D. Hi Pressure Fluid Hose 25;
APPENDIX B (CONTINUED) AIR TYPE SPRAY E UIPMENT UANTITY DESCRIPTION OF E UIPMENT 1 Each 10:1 President Spray Pump 1 Each Air Powered Ram 1 Each Heavy Mastic Spray Gun 1 Each Special Dump Valve 2 Each 1/4 Inch or 1/4 Inch "E" Spray Tip 1 Each Air Agitator 1 Each Air Regulator Kit 1 Each Air Regulator Only with Gauge 1 Each Air Line Lubricator 1 Each Air Line Filter 5 Each Pump Repair Parts Kits 75 Feet 1/2 Inch I.D. Hi-Pressure Fluid Hose 25 Feet 3/8 Inch I.D. Hi-Pressure Fluid Hose 26
APPENDIX C APPLICATION PROCEDURES STRUCTURAL STEEL ENTITIES
~~l. 0 INTRODUCTION This procedure sets for the sequential steps involved in applying THERMO-LAG 330-1 Subliming Coating System to structural steel entities and steel storage tanks.~~
~~The THERMO-LAG 330-1 Subliming Coating System consists of THERMO-LAG Primer, THERMO-LAG 330-1 Subliming Coating, and where applicable, THERMO-LAG Topcoat.~~
~~2. 0 SURFACE PREPARATION 2.1 All surfaces to be coated are to be clean, dry, above 40'F, and free from scale, rust and other contaminants.~~
2.2 Prepare non-compatible surfaces for coating by applying a barrier coat of THERMO-LAG 351 or THERMO-LAG 351-2 Primer'. Never apply the primer directly over a surface previously primed with a zinc . based primer without installing a barrier coat. Never apply the primer directly over any hard or glossy paint without roughening the surface in accordance'ith standard, good painting, practice procedures and make sure that the cleaned substrate is compatible with the THERMO-LAG 330-1 Subliming Coating by making cross hatch adhesion tests. 2.3 Blast clean doubtful surfaces to an SSPC-SP6 finish and reprime immediately. 27
3.0 PRIMER APPLICATION 3.1 Apply the primer- to a properly prepared steel surface in one continous coat using spray equipment or a roller. The minimum acceptable dry primer thickness should be 0.002 inches which is normally achieved by applying at a rate of 200 square feet per gallon. 3.2 Measure primer thickness using an approved magnetic direct reading gauge. 3.3 Make cross hatch adhesion tests, as per Federal Standard 141A, on the primed surface to assure proper adhesion between the primer and the'teel substrate prior to proceeding with the application of the THERMO-LAG 330-1 Subliming Coating. 3.4 Make at least one cross hatch adhesion test every twenty (20) square feet of primed surface area. Any primed surface area which fails the cross hatch adhesion test shall be sandblasted to an SSPC-SPC6 commercial blast finish and then shall be reprimed with THERMO-LAG 351 or THERMO-LAG 351-2 Primer. 4.0 THERMO-LAG 330-1 SUBLIMING COATING 4.1 Apply the material in as many passes as required to provide the required film build or thickness, taking care to avoid slumping or sagging of the coating. The thickness which can be safely applied in a single pass will depend upon the temperature, humidity, application technique, and other factors and should be determined at the gob site. 4.2 Apply the material in smooth even passes, taking care to keep the spray gun fan pattern at a 90'ngle whenever possible. Reaching with a spray gun will cause the spray pattern to vary from the and will result in a rougher surface than normal. 90'ngle 28
4.3 Take frequent wet thickness measurements during the application using a penetration measuring device such as those shown in Appendix A to ensure that the coating is being applied uniformly and at the required wet film thickness. These w'et thickness checks shall be made very five square feet or every two running. feet of coated surface area. (Note: When taking measurements allow for a shrinkage rate of 25%'between the wet and the desired dry film coating thickness. 4.4 Remove excess build up of coating material at edges and points by brushing or rolling the surface with a damp sponge roller. 4.5 Spray edges of the substrate from each side to cause the material to wrap around the edge. If the edge coating is not completely closed, use a wet roller or trowel to seal the edge surface. 4.6 Apply Fiberglass Armoring, where required, to the wet surface after the final pass and use a roller to flatten out any wrinkles and to embed the fiberglass securely.. Then apply sufficient coating material to cover the embedded fiberglass. 4.7 Remove all runs, sags, drips or other surface imperfections before the material cures using wet sponge rollers, brushes or hand trowels. 4.8 Take dry film thickness measurements after the applied material has cured. Measurements shall be made using'electrical, penetrating or magnetic measuring instruments. 5.0 . TOPCOAT APPLICATION 5.1 Insure that the area to -be topcoated is free from loos'e and foreign matter. 5.2 Take moisture meter readings of the applied subliming coated surface a Delmhorst Moisture Meter (Model DP) or equivalent.'btain 'sing a reading of 20 or less before applying the to'pcoat. 29
I 5.3 Place mixed material into spray rig. 5.4 Apply topcoat in two continuous coats at a minimum spread rate. of 50 square feet per gallon in a smooth even .pattern, making sure to criss-cross 'the area in a continuous film., 6.0 CLam UP 6.1 A clean and orderly condition shall be maintained in the application area. Following the application, all overspray, debris and equipment shall be removed and the area left in a condition acceptable to the. owner. 30
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$(
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OUTLINE OF'TSI'S QUALITY ASSURANCE AND QUAL'ITY CONTROL SYSTEM EFFECTIVITY AND APPROVAL NQAP l-l INTRODUCTION 1.1 Scope 1.2 Applicability 1.3 Responsibility 1.4 Definitions 1.5 Documents NQAP 2-1 QUALITY ASSURA."tCE PROGRAM 2.1 Program Description 2.2 Organization 2.3 Design Control 2.4 Procurement Document Control 2.5 Instructions and Procedures
2. 6 Document Control

2. 7 Procurement Control 2.8 Material Parts and Components Control 2.9 Special Process Control 2.10 Inspection 2:ll Test Control 2..12 Test Equipment Control 2.13 Receiving and Storage Control II

2. 14 Inspection, Test and Operating Status
I 2.15 Noncomformance Control 2.16 Corrective Action Control 2.17 Quality Assurance Records 2.18 Audits NQAP.3-1 ORGANIZATION 3.1 Introduction 3.2 Organization Structure 3.3 Responsibilities and Authority 3.4 Internal and External Communication NQAP 4-1 DESIGN CONTROL 4.1 Introduction 4.2 Applicable Documents 4.3 Responsibility 4.4 Design Documents 4.5 Design Reviews 4.6 Design Interface Control 4.7 Design Changes 4.8 Records NQAP 5-1 PROCUREMENT DOCUMENT CONTROL 5.1 Introduction 5.2 Responsibility 5.3 Procedures 5.4 Records NQAP 6-1 INSTRUCTIONS AND PROCEDURES
6. 1 Introduction

6. 2 Responsibility 6.3 Procedures 6.4 Records NQAP 7-1 DOCUMENT CONTROL

7. 1 Introduction

7. 2 Responsibility 7.3 Nuclear Quality Assurance Program Manual 7.4 Quality Control Procedures 7;5 Other Controlled Documents NQAP.8-1 PROCURPKNT CONTROL 8.1 Introduction 8.2 Responsibility 8.3 Purchase Requisitions 8.4 Purchasing 8.5 Qualified Vendors 8.6 Records NQAP 9-1 MATERIAL, PARTS AND COMPONENTS CONTROL

9. 1 Introduction 9; 2 I Applicable Documents 9.3 Responsibility

9. 4 Materials 9.5 ., Inspection and Tests

9. 6 Documentation

9. 7 Records
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NQAP 10-1 SPECIAL PROCESS CONTROL 10.1 Introduction 1.0.2 Responsibility 10.3 Special P'rocess'Procedures 10.4 Qualification and Certification of Special Process Record 10.5 Records NQAP ll-l INSPECTION 11.1 Inspection 11.2 Responsibility 11.3 Procedures 11.4 Records NQAP 12-1 TEST CONTROL 12.1 Inspection 12.2 Responsibility 12.3 Procedures 12.4 Test Control 12.5 Records NQAP 13-1 TEST EQUIPMENT CONTROL 13.1 Introduction 13.2 Responsibility 13.3 Operating Procedures 13.4 Measurement Validity 13.5 Identification and Documentation 13.6 Qualifications of Personnel
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13.7'Records NQAP 14-1 RECEIVING AND STORAGE CONTROL 14.1 Introduction 14.2 Responsibility 14.3 Receiving 14.4 Storage 14.5 Issue 14.6 Shipping 14.7 Records NQAP 15-1 INSPECTION, TEST AM) OPERATING STATUS 15.1 Introduction 15.2 Responsibility 15.3 Procedures 15.4 Records NQAP 16-1 DEVIATION AND NONCONFORMANCE REPORTS 16.1 Introduction 16.2 Responsibility 16.3 Deviation and Nonconformance Reports 16.4 Stop Work Authority 16.5 Client Reports 16.6'ecords NQAP 17-1 CORRECTIVE ACTION CONTROL 17.1 Introduction 17.2 Responsibility 17.3 Procedures
17.4 Records NQAP 18-1 QUALITY ASSURANCE RECORDS 18.1 Introduction 18.2 Responsibility 18.3 Procedures 18.4 Records NQAP 19-1 AUDITS 19.1 Introduction 19.2 Applicable Documents 19.3 Responsibility 19.4 Procedures 19.5 Records}}

ML17139A456

Contents

Text

Subject:

SUMMARY

Subject:

Dear Mr. Feldman:

Dear Dr. Feldman:

Dear Or. Feldman:

Dear Dr. Feldman:

Subject:

Dear hir. Levine:

1.0 INTRODUCTION

1.0 INTRODUCTION

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ML17139A456

Text

Subject:

SUMMARY

Subject:

Dear Mr. Feldman:

Dear Dr. Feldman:

Dear Or. Feldman:

Dear Dr. Feldman:

Subject:

Dear hir. Levine:

1.0 INTRODUCTION

1.0 INTRODUCTION

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