J U L Y 2 0 0 8

F I R E P R O T E C T I O N D E S I G N F O R S T R U C T U R A L S T E E L

C A B L E E N C L O S U R E & S E L F - S U P P O R T I N G D U C T

Screws at

190mm centres

steel anglefixed to concreteat 300mm centresSelf-tappingscrews at285mm centres

ERMICULUX® is a low density lightweightnon-combustible board made from a blend ofvermiculite and reinforced with selected

inorganic fibres and fillers. It is formulated and speciallydesigned to provide fire protection to structural steel.VERMICULUX® boards can provide up to 240 minutes of fireresistance in accordance with the criteria of BS476: Part 21: 1987;depending on the thickness of material used and the dimensions of thebeam or column being protected.VERMICULUX® boards are off-white in colour with a sanded finish on bothfaces. They can be left undecorated or easily painted.VERMICULUX® boards are resistant to moisture, will not disintegrate, warp or swell and canbe installed at any time during the building programme, even before external walls have beencompleted and the building made weathertight.VERMICULUX® boards are easy to work using normal woodworkingtools and are supplied with two rebated edges to allow cross joints to bemade without the noggings, cover strips or adhesives.

Fixed by edge screwing boards together, VERMICULUX® boards are fastand economic to install. It is also suitable for the protection of cast-ironcolumns and beams, and construction of ducts and services enclosures.

Typical examples of beamand column claddingsusing VERMICULUX® board

( T E C H N I C A L P R O P E R T I E S )( T E C H N I C A L P R O P E R T I E S )All VERMICULUX® board sizes are based on metric

equivalents of imperial dimensions rounded to the nearest

5mm. Standard sizes and board tolerances are outlined below.

Non-standard sizes sometimes are available upon request.

20mm, 25mm, 30mm, 35mm, 40mm, 45mm,

THICKNESS 50mm, 55mm and 60mm

LENGTH x WIDTH 1220mm x 610mm or 1220mm x 1220mm

TOLERANCES Thickness: +0mm to -0.8mm

Length: +0mm to -1.5mm

Width: +0mm to -1.5mm

ALKALINITY 7~10pH

NOMINAL DENSITY (dry) 500kg/m3

NOMINAL WEIGHT 20mm: 10.3kg/m2

(at ambient conditions and EMC) 25mm: 12.9kg/m2

30mm: 15.5kg/m2

35mm: 18.1kg/m2

40mm: 20.6kg/m2

45mm: 23.2kg/m2

50mm: 25.8kg/m2

55mm: 28.4kg/m2

60mm: 30.9kg/m2

FLEXURAL STRENGTH, Frupture (average, dry) 2.0N/mm2

MODULUS OF ELASTICITY, E (average, dry) 1.4GN/m2

Non-combustible in accordance with

COMBUSTIBILITY the criteria of BS 476: Part 4: 1984.

Class 1 (in accordance with

SURFACE SPREAD OF FLAME the criteria of BS 476: Part 7: 1987)

Class 0 (as defined in the appropriate

BUILDING REGULATIONS CLASSIFICATION Building Regulations)

NOMINAL MOISTURE CONTENT (air dried) 3%

MOISTURE MOVEMENT

(35% to 85% RH at 20OC, ambient to saturated) ≤0.1%

THERMAL CONDUCTIVITY (approximate at 20OC) 0.13W/mK

COEFFICIENT Of THERMAL EXPANSION

(20OC to 100OC per m/mK) 7.5 x 10-8

all figures are approximately based on average standard production values. If a particular property is important, please CONTACT Intumex AsiaPacific TO OBTAIN THE RELEVANT INFORMATION. a Material Safety Data Sheet IS ALSO AVAILABLE FOR REQUEST.

Encasement

(A)

Circular

hollow

section

(A)

4 sides (πD)

4 sides (2D + 2B) 3 sides (2D + 2B) 3 sides (2d + B) 2 sides (D + B) 1 side (B)

B

D

D

d

( S T r u c t u r a l s t e e l( S T r u c t u r a l s t e e lD E S I G N C O N S I D E R A T I O N )D E S I G N C O N S I D E R A T I O N )

Specifications of

Steelwork Section Factor

The Hp/A (Heated perimeter/Area) is a measure of the

rate at which a specific steel section will heat up when

exposed to fire.

The higher its value, the greater the thickness of fire

protection is required.

Hp/A = Rectangular perimeter of exposed steelwork (m)

(m-1) Cross-sectional area of the steel section (m-2)

Calculation of Hp/A factors

1) Find the actual depth (D) and width (B) in metres of

the steel section from supplier’s literature, or site

measurements.

2) Refer to T a b l e 1 for the extent of exposure, and

calculate Hp.

3) Find the cross-sectional area A in square metres of

the section from supplier’s literature, or site

measurements. For partial exposed members the A

value is still the total cross-sectional area.

4) Divide Hp by A to give Hp/A in m-1. Please refer to

supplier’s literature book for Hp/A values.

For partial exposed members, the value is still the total cross-sectional area.

An example for universal beam, exposed on 3 sides:

Serial size = 475mm x 152mm x 82kg/m

Actual size (D x B) = 465.1mm x 153.5mm

Hp (2D + B) = (2 x 465.1)mm + 153.5mm = 1083.7mm = 1.0837m

A = 104.5cm2 = 0.01045m2

Hp/A = 1.0837m / 0.01045m2 = 103.7m-1 = 104m-1

( S T r u c t u r a l s t e e l D E S I G N C O N S I D E R A T I O N )( S T r u c t u r a l s t e e l D E S I G N C O N S I D E R A T I O N )

260 260 260 260 260 260 260

250 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––250

240 –––––––––––––––––––––––––––––––––––––––35mm–––––––55mm ––––––––––––––––240

230 –––––––––––––––––––––––––––25mm ––––––––––––––––––––––––––––––––––––––––230

220 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––220

210–––––––––––––––––––––––––––––––––––––––––––––––––––50mm ––––––––––––––––210

200 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––200

190 –––––––––––––––––––––––––––––––––––––––30mm ––––––––––––––––––––––––––––190

180 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––180

170–––––––––––––––––––––––––––––––––––––––––––––––––––45mm ––––––––––––––––170

160 ––––––––––––––––––––––––––––––––––––––– –––––––––––––––––––––––––––––––– 160

150 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––150

140 –––––––––––––––––––––––––––––––––––––––25mm–––––––40mm ––––––––––––––––140

130––––20mm–––––––20mm –––––––––––––––––––––––––––––– –––– ––––––––––––––––130

120 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––120

110 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––110

100 –––––––––––––––––––––––––––20mm –––––––––––––––––––––––––––––– –––––––––100

090–––––––––––––––––––––––––––––––––––––––––––––––––––30mm–––––––40mm–––––900

080––––––––––––––––––––––––––––––––––––––––––––––––––– –––– ––––––––––––––––800

070–––––––––––––––––––––––––––––––––––––––––––––––––––25mm ––––––––––––––––700

060 –––––––––––––––––––––––––––––––––––––––20mm ––––––– –––– –––––––30mm–––––600

050 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––500

040 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––400

030–––––––––––––––––––––––––––––––––––––––––––––––––––20mm–––––––25mm–––––300

020 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––200

010 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––100

30 60 90 120 180 240

PERIOD OF FIRE RESISTANCE (minutes)

VERMICULUX® boards can provide up to 240 minutes of fire resistance period for structural steel in

accordance with the criteria of BS476: Part 21: 1987. The above table is based on critical steel temperature

of 550°C. Please consult Intumex Asia Pacific for other parameters or temperatures.

45mm

55mm

60mm

50mm

35mm

35mm

A/V

(m

-1)

–227–

–215–

–159–

–114–

–202–

–189–

–156–

–128–

–103–

–081–

–061–

–155–

–134–

–115–

–098–

–082–

–067–

–054–

–178–

A

Y X

1)

2)

3)

( S T r u c t u r a l( S T r u c t u r a l s t e e l b e a m )s t e e l b e a m )

Example of a three-sided

structural beam cladding

1) Steel angles are fixed on both sides of the

beam. Take the measurement between

the outside faces of the angles (A).

Measure the depth of the beam (Y) and

add 6mm plus the thickness of the

VERMICULUX® board (X). Cut the

boards, one to dimension A and two

to dimension X.

Fix the two boards using the self-tapping

screws or dry wall screws into the angles.

2) Fix the remaining board between the side

panels with all transverse joints staggered.

3) Repeat the above along the length of the

beam structure.

1)

2)

3)

( S T R U C T U R A L S T E E L C O L U M N )

Example of a four-sided

structural column cladding

1) Measure the column and add 6mm to

each dimension to provide 3mm all-

round clearance.

Add twice the thickness of the

VERMICULUX® board to the web

dimension. Determine the most

economic way to cut the boards, and

cut the board so that the rebate will be at

the transverse joint.

Make up a three-sided box by edge

screwing the VERMICULUX® boards.

2) Remove the rebate from the bottom of all

four sides of the first sections and ensure

that the casing is level and square.

Place the three-sided box in position and

fix the fourth side.

3) Repeat the above steps up to the column,

bearing in mind that the rebates are

reversed on alternate sections.

100mm

( C A B L E S E N C L O S U R E )

100mm

VERMICULUX® boards can provide up to 90 minutes of fire

resistance level (FRL) for cables and services enclosure in

external fire exposure in accordance with the criteria of BS476:

Part 20: 1987 thereby maintaining the functionality of essential

cables in a fire.

FRL30 60 90

minutes minutes minutes

Enclosure ≤100mm x 100mm(1)

size 350mm x 170mm to 760mm x 300mm(2)

Thickness30mm(1) 50mm/2 x 25mm(1) 2 x 35mm(1)

25mm(2) 45mm/20+25mm(2) 2 x 30mm(2)

(1) Type 1 of cables enclosure(2) Type 2 of cables enclosure

Casing

One or two layers of VERMICULUX® board

(see T a b l e 3 for thickness) edge screwed

at 200mm centres.

Cover strips

VERMICULUX® 25mm thick x 125mm

wide, fixed over joints. For single layer duct

constructions, cover strips should be fixed to

the external faces of the top and sides with

the bottom strip inside the duct.

For double layer constructions, board joints

are staggered and cover strips need only to

be fixed to the inside at the bottom of the

duct. Cables should be supported on trays

but these can be omitted if the bottom

internal cover strip has been fixed at

600mm centres.

Supports

M10 threaded rods fixed by means of plugs

into concrete soffit. Tensile stress in rods

should not exceed 6N/mm2.

100mm

100mm

Casing

Two layers of VERMICULUX® board

(see T a b l e 4 for thickness) edge screwed

with 60mm x 5mm woodscrews at 195mm

centres.

Layers offset at circumferential joints to

form 100mm lap; boards screwed together

with 35mm x 4mm, 45mm x 4mm and

50mm x 4mm woodscrews in three rows

100mm apart. The central row is located in

centre of lap, the screws in each row at

150mm centres. Screws must be inserted

from outside of the duct.

Supports

8mm diameter threaded rods and 15mm x

30mm x 15mm x 5 mm steel channel rails at

1220mm centres near circumferential joints.

Filler

Joints and screw heads are filled using

a m i x t u r e o f s o d i u m s i l i c a t e a n d

VERMICULUX® powder.

( S E L F - S U P P O R T I N G D U C T )( S E L F - S U P P O R T I N G D U C T )

FRL60 90 120

minutes minutes minutes

Internal layer

Thickness 2 x 20mm 2 x 25mm30mm,

external layer

25mm

VERMICULUX® boards are suitable for protecting smoke

extraction ducts in buildings where the means of escape could be

severely contaminated with smoke and become impassable.

The boards can provide up to 120 minutes fire resistance level

(FRL) for self-supporting integrity and insulation duct in

accordance with the criteria of BS476: Part 24: 1987.

Maximum duct size is up to 750mm x 300mm.

( W O R K I N G )( W O R K I N G )

General

Use normal woodworking tools.

Cutting

Use a fine-toothed panel saw. For shaped cuts

use a padsaw, keyhole saw or coping saw. Work

with fair face upwards and support the board as

cutting progresses. Quick and easy rough cuts

can be made by scoring thin boards with a

Stanley knife and snapping over a straight edge.

For power sawing use a tungsten carbide or

diamond tipped blade.

Drilling

Use normal low or high-speed drills. Place scrap

board under the drilling location to ensure a

clean hole.

Smoothing

Smooth cut edges with a Surform plane, rasp

or file.

Sanding

Sand with conventional papers. Garnet paper is

best for fine sanding.

( F I X I N G )( F I X I N G )

Refer to the specifications for full recom-

mendations for type, size and spacing of fixings.

All fixings should be rust proof.

Jointing

Board joints should be tight butted. Joints and

screw holes can be filled and sanded to a smooth

flat surface.

If the fire resistant system requires an expansion

or compression movement joint, please consult

Intumex Asia Pacific.

( D E C O R A T I N G )( D E C O R A T I N G )

Painting & Coating

Prime boards before painting. For water-based

paints apply a watered-down first coat; for oil-

based paints use a universal primer; for textured

paints use manufacturer’s recommended sealer.

Alkali-resistant primers are not required.

Where an easily-cleaned finish is required, apply

Steridex or similar liquid plastic coating.

Vapour transmission can be reduced by

applying a priming coat followed by two

undiluted coats of chlorinated rubber paint,

epoxy resin paint, polyurethane or liquid plastic.

Rendering

Resin-based textured finishes such as Highbuild

and Cullaplast can be applied after first sealing

the boards with Sandtex stabilising solution.

Cement-based rendering should only be applied

over expanded metal lathing.

Papering

Boards should be well sized before hanging

wallpaper. All types of paper and vinyl can be

used. Vinyl wall coverings can be easily stripped

from the boards for re-decoration.

Plastering

Boards may be plastered using:

1) Snowplast, applied after first sealing boards

with two coats of Cemprover PVA.

2) Artex, applied as a smooth coating direct to

the board.

3) Carlite Browning HSB (undercoat plaster for

high suction substrates) followed by Carlite

Finish.

( m a i n t e n a n c e & c l e a n i n g )( m a i n t e n a n c e & c l e a n i n g )

If VERMICULUX® boards are broken or cracked, they should be replaced rather than repaired in order to

ensure fire performance is maintained.

Undecorated boards do not require any special cleaning. Where cleaning is necessary for cosmetic

purposes, they may be vacuumed, or sanded to remove marks. Although moisture will not harm the boards,

excessive use of water in cleaning is not recommended as the boards will take time to dry out.

Decorated boards should be re-decorated as necessary to retain appearance, following the

recommendations of the manufacturer of the decorative system.

( H A N D L I N G & S T( H A N D L I N G & S T O R A G E )O R A G E )

Carry VERMICULUX® boards on edge and do not drop on their corners or onto trestles. All boards should

be stored under cover on a flat base, clear of the ground.

If stored in the open, the stack should be fully protected from the weather. If stored on racks or dunnage,

boards should be fully supported across their width at not more than 1000mm centres.

( H E A L( H E A L T H & S A F E T Y )T H & S A F E T Y )

VERMICULUX® boards will support their own weight, but are non-loadbearing. Horizontal boards must

not be walked on as they are not designed to take additional loads between supports. If there is a risk of this

occurring, warning notice should be displayed. Fixers must ensure that they work from adequate and safe

platforms where necessary.

VERMICULUX® products are formulated without inorganic fibres and no special precautions are necessary

in handling or working. However, when using power saws or sanders in a confined space or working with

materials which can create dust, dust extraction equipment is recommended and appropriate dust masks

and other P.P.E. should be worn at all times.

When machining, airborne dust may be released. Avoid contact with skin and eyes. Use dust extraction

equipment. Respect regulatory occupational exposure limits for total inhalable and respirable dust.

For more information, please contact your nearest Intumex Asia Pacific office for the Material

Safety Data Sheet.

Intumex Asia Pacific

HONG KONGRoom 1011, C.C. Wu Building

302-308 Hennessy RoadWanchai

Tel: +852 2895 0265Fax: +852 2576 0216

AUSTRALIAUnit 1, 175 Briens RoadNorthmead, NSW 2152Tel: +61 (2) 9683 2872Fax: +61 (2) 9630 0258

SINGAPORE10 Science Park Road

#03-14 The AlphaSingapore Science Park II

Singapore 117684Tel: +65 6292 7888Fax: +65 6294 2576

Email: info@intumex-ap.com

www.intumex-ap.com

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