SOBEN INTERNATIONAL (ASIA PACIFIC) LTD Soben...board joints are coincident with the channels and are...

This certificate is the property of Warrington Certification Limited, Holmesfield Road, Warrington, Cheshire WA1 2DS, UK. Registered company No. 02250182.

Signed and sealed for and on behalf of CERTIFIRE

Sir Ken Knight Paul Duggan Chairman Certification Manager

WCL Impartiality Committee Warrington Certification Ltd

CERTIFICATE OF APPROVAL No CF 5413

This is to certify that, in accordance with

TS00 General Requirements for Certification of Fire Protection Products The undermentioned products of

1

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SOBEN INTERNATIONAL (ASIA PACIFIC) LTD

Unit 4A, Evernew Commercial Centre, 33 Pine Street, Kowloon, Hong Kong

Tel: +852 31732683

Have been assessed against the requirements of the Technical Schedule(s) denoted below and are approved for use subject to the conditions

appended hereto: _____________________________________________________________________________________________________

CERTIFIED PRODUCT TECHNICAL SCHEDULE

Soben International FirePro/FP-900 Steel Ductwork System

TS48 - Smoke Control and Fire Resisting Ductwork Systems

Issued: 24th March 2016

Valid to: 23rd

March 2021


CERTIFICATE No CF 5413


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SOBEN INTERNATIONAL – FirePro/FP-900 Steel Ventilation, Smoke Outlet and Kitchen Extraction Ductwork Systems

1. This approval relates to the use of the above ductwork systems in providing fire resistance

of up to 240 minutes stability, integrity and insulation, as defined in BS 476: Part 24: 1987

(ISO 6944: 1985). Subject to the undermentioned conditions, the ductwork systems will

meet the relevant requirements of BS 9999 for fire resisting compartment ductwork

systems, for periods of up to 240 minutes (dependent upon design limitations) when used

in accordance with the provisions therein.

2. This certification is designed to demonstrate compliance of the product or system

specifically with Approved Document B (England and Wales), Section D of the Technical Standards (Scotland), Technical Booklet E (N. Ireland). If compliance is required to other regulatory or guidance documents there may be additional considerations or conflict to be taken into account.’

3. The ductwork systems are approved on the basis of: i) Initial type testing ii) Audit testing at the frequency specified in TS48 iii) A design appraisal against TS48 iv) Certification of quality management system to ISO 9001:2008 v) Inspection and surveillance of factory production control

4. The ductwork systems comprise FirePro/FP-900 board supported by GI angle sections at

the longitudinal system corners and collars formed from GI channels around a steel duct,

with Rockwool insulation fitted to some constructions between the board and the steel

duct.

5. This approval is applicable to insulated and partially insulated FirePro/FP-900 steel

ductwork systems as described within this Certificate.

6. The ductwork systems shall be mechanically supported from floor and/or wall constructions

or structural steel members having a fire resistance of at least the same period as the

ductwork systems.

7. The approval relates to on going production. Product and/or its immediate packaging is

identified with the manufacturers’ name, the product name or number, the CERTIFIRE

name or name and mark, together with the CERTIFIRE certificate number and application

where appropriate.




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SOBEN INTERNATIONAL – FirePro/FP-900 Steel Duct Systems Horizontal Ducts

Steel Duct Assemblies

The steel duct is constructed with minimum 0.6mm-thick galvanised steel sheet with longitudinal

seams formed using the Pittsburgh Lock or Grooved Corner Seam systems. The steel ducts

must be constructed with rolled steel angle flanged cross-joints or equivalent roll formed sheet

steel profile cross-joints. The maximum section length is 1500mm. General guidance on the

construction of steel ductwork is given in DW/144 – ‘Specification for Sheet Metal Ductwork –

Low, medium and high pressure/velocity air systems’ published by the Building and Engineering

Services Association.

For steel duct sizes other than those tested, up to a maximum size of 7500mm wide x 2500mm

high, the minimum thickness of the steel sheet and the minimum size of the angle for the cross

joints must be as shown in Table 1.

Table1. Minimum Construction Requirements for Steel Ducts

Maximum size of duct longer side

mm

Thickness of steel sheet

mm

Size of cross joint angle

mm x mm x mm

Stiffening collar

required

≤ 400 0.6 25 x 25 x 3 No

401 to 1000 0.8 30 x 30 x 3 No

1001 to 1500 1.0 30 x 30 x 4 Yes

1501 to 2500 1.0 40 x 40 x 4 Yes

2501 to 3000 1.2 50 x 50 x 5 Yes

3001 to 6000 1.2 70 x 70 x 6 Yes

6001 to 7500 1.2 80 x 80 x 6 Yes

The rolled steel angles of the cross joints are welded at the corners and fastened to the duct walls with minimum 5mm-diameter steel rivets (or equivalent) at maximum 150mm centres or spot-welded at 75mm nominal centres. The cross joints of adjacent sections are fastened with M10 steel bolts at the corners and at 300mm maximum centres along each of the four sides. If equivalent roll formed sheet steel profile cross-joints are fitted then the cross joints of adjacent sections are fastened with M10 steel bolts at the corners and steel clamps at 150mm maximum centres along each of the four sides.




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For ducts over 1000mm wide, stiffening collars are required, as shown in Table 1, for ducts with a section length greater than 625mm. Each collar is fitted at approximately mid-length of the duct section and is made of the same size of steel angle as used for the cross joints (or equivalent). The angles are welded or bolted together at the corners and fastened to the duct walls with minimum 5mm-diameter steel rivets (or equivalent) at maximum 300mm centres. Duct Supports The duct is supported by steel hangers that consist of a pair of threaded drop rods and an angle or channel bearer under the steel duct. The spacing of the hangers and the size of the steel hanger components must be adjusted so that the tensile stress in the rods and the bending stress in the bearers do not exceed 15N/mm

2 for 60 minutes fire resistance, 10N/mm

2 for 120

minutes fire resistance, 8N/mm2 for 180 minutes fire resistance and 6N/mm

2 for 240 minutes fire

resistance. The maximum spacing of the hangers is 1200mm. The hangers should be positioned within 150mm of the duct section joints or stiffening collars. The fixings used to fasten the threaded rod hangers to concrete soffits must be all-steel expanding anchors (e.g. Hilti HKD anchors) with a penetration in the concrete of at least 40mm for 60 minutes fire resistance, 50mm for 120 minutes fire resistance and 60mm for 240 minutes fire resistance. The anchors must match the size of the threaded rods, be of sufficient strength to support the weight of the duct and be fitted in accordance with the manufacturer's instructions. When the hanger rods are suspended from protected structural steel beams, they must be protected for at least 300 mm from the beams with the same level of protection as the structural beams. When hangers exceed 2.0m in length, (1.5m for those hangers adjacent to wall penetrations), the hangers should be clad with a material of similar thickness to the duct to prevent excessive thermal expansion. FirePro/FP-900 Board Installation

Steel channel collars are folded around the duct. The collars are positioned at maximum 600mm centres for insulated and uninsulated ventilation, smoke outlet and kitchen extract ducts except for uninsulated ventilation ducts with a fire rating up to 120 minutes for which the collars may be positioned at 1200mm maximum centres. The collars are steel channels, minimum 32mm flanges x 50mm web x 0.8mm thick, which are fastened together at the corners with steel rivets or self-tapping screws. The channels are not directly fastened to the duct except for ducts with a width greater than 1500mm where the channels under the soffit of the duct and the channels up the sides of the duct must be fastened to either the cross joint angles or the stiffening collar angles with either steel self-tapping screws or steel rivets at 300mm nominal centres. The corners of the collars are connected with longitudinal steel angles, minimum 50mm x 50mm x 0.8mm thick, which are fastened to the collars with steel rivets or self-tapping screws.

Where the depth of the flanged cross-joints or the hanger bearer is greater than 32mm, the depth of the channel collars must be increased to suit.




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FirePro/FP-900 boards, 9, 12, 14, 18 or 24mm thick, are screwed to the channel collars and the longitudinal angles with M3.8 steel self-tapping screws at 250mm maximum centres. Transverse board joints are coincident with the channels and are covered with a FirePro/FP-900 board cover strip, 100mm wide x 12mm thick, which is fastened to the channel collars, on both sides of the joint, with M3.8 steel self-tapping screws at 250mm maximum centres. Alternatively, for un-insulated duct assemblies, transverse board joints are sealed with Hilti CP601S silicone sealant, or equivalent fire rated sealant, instead of the fitting of board cover strips. The maximum area of unsupported board is 1.5m

2. In order to achieve this for larger duct sizes

either the spacing of the channel collars is reduced or longitudinal channels (the same size as the collars) are fitted between the transverse collars and connected to them. Any longitudinal board joint in the FirePro/FP-900 (other than a corner joint) must be backed by a steel channel (the same size as the collars) and fitted with a FirePro/FP-900 cover strip. The longitudinal channel must be fastened to the channel collars with steel rivets or self-tapping screws. Where the hanger drop rods pass through the FirePro/FP-900 board the penetrations are sealed with a fire-rated acrylic sealant or equivalent. Penetrations At wall penetrations steel angle collars, 150mm x 100mm x 0.8mm thick, and L-shaped collars of FirePro/FP-900 boards are fitted around the duct on both sides of the wall. The board collars are made of strips at least 150mm wide x the same thickness as the protection around the steel duct, except for system 14B (insulated 240 minute duct B) where the thickness of the FirePro/FP-900 collar around the duct must be increased from 24mm to 32mm. The steel and board collars are fastened to the wall with M8 all-steel expanding anchors at 400mm maximum centres. A steel channel collar is fitted around the steel duct on both sides of the wall. The steel and board collars are fastened to the channel collars, through the FirePro/FP-900 board around the duct, with M3.8 steel self-tapping screws at 250mm maximum centres. The space between the FirePro/FP-900 casing and the reveals of the opening and between the FirePro/FP-900 casing and the steel duct, for the depth of the wall, must be filled with rock wool of minimum density 100kg/m

3. The collars are sealed against the wall with fire-rated acrylic sealant.

Insulated Ducts On the duct systems where 30, 60, 120, 180 or 240 minutes insulation performance is required, rock wool insulation is fitted around the steel duct. The joints in the Rockwool batts are tight butt joints and, if fitted in more than one layer, should be staggered between layers by at least 150mm. The steel channel collars are also filled with the Rockwool. The thicknesses of FirePro/FP-900 board and Rockwool for the various fire resistance ratings are given in Table 2 for duct type A and table 3 for duct type B.




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Table 2. - Duct A

System

Fire resistance - minutes Duct A

Stability Integrity Insulation FirePro/FP-900

mm

Rockwool

mm x kg/m3

1A 60 60 - 12 -

2A 60 60 60 12 30 x 60

3A 120 120 - 12 -

4A 120 120 30 12 25 x 60

5A 120 120 60 12 30 x 60

6A 120 120 120 12 50 x 60

7A 180 180 - 12 -

8A 180 180 180 14 50 x 100

9A 240 240 - 12 -

10A 240 240 30 14 25 x 60

11A 240 240 60 14 30 x 60

12A 240 240 120 14 50 x 60

13A 240 240 180 14 50 x 100

14A 240 240 240 18 or 2 x 9 50 x 120

Table 3. - Duct B

System

Fire resistance - minutes Duct B


mm

Rockwool

mm x kg/m3

1B 60 60 - 12 -

2B 60 60 60 12 50 x 60

3B 120 120 - 12 -

4B 120 120 30 12 30 x 60

5B 120 120 60 12 50 x 60

6B 120 120 120 14 50 x 100

7B 180 180 - 14 -

8B 180 180 180 24 80 x 100

9B 240 240 - 14 -

10B 240 240 30 24 -

11B 240 240 60 24 50 x 60

12B 240 240 120 24 50 x 100

13B 240 240 180 24 80 x 100

14B 240 240 240 24 100 x 100




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One, Two & Three Sided Ducts A one, two or three-sided FirePro/FP-900 steel duct can be constructed using the adjacent concrete/masonry walls and floor slab to support the assembly, provided that the surrounding building elements have a fire resistance equal to or higher than the fire resistance required for the duct. The steel duct and hanger supports are the same as for the 4-sided duct arrangement as described above. The steel channel collars are fitted around one, two or three sides of the steel duct, in a similar way to the 4-sided system, except that the ends of the channels are fixed to minimum 50mm x 50mm x 1.2mm angles anchored to the wall or floor elements with minimum M8 all-steel expanding anchor bolts at 400mm maximum centres. A bead of fire-rated acrylic sealant is fitted between the angles and the wall or floor. The channels are fastened to the angles with minimum two M3.8 steel self-tapping screws or M4 steel rivets at each junction. The size and spacing of the screws and anchors must be adjusted depending on the weight of the duct assembly. The maximum bearing, tensile and shear stresses for the steel angles, screws and anchors is 15N/mm

2 for a fire exposure of 60 minutes, 10N/mm

2 for a fire exposure of 120 minutes, 8N/mm

2

for 180 minutes fire resistance and 6N/mm2 for a fire exposure of 240 minutes.

For steel ducts over 1500mm wide the channels under the soffit of the duct must be fastened to either the cross-joint angles or the stiffening collar angles as for the 4-sided duct. The maximum size of steel duct is 7500mm wide x 2500mm high. The FirePro/FP-900 boards are fastened to the channels and angles in the same way as for the 4-sided duct system. The FirePro/FP-900 cover strip, fitted at board joints, may be placed either outside of the board enclosure, as tested, or placed in between the steel channel collar and the board enclosure. The penetration seal system is the same as for the 4-sided duct system. Kitchen Extraction Ducts Where the duct system is to be used as a kitchen extract duct, the non-mandatory annex to B.S. 476: Part 24: 1987 recommends that the ducts are not lined with combustible materials, which are likely to accumulate combustible deposits, and that the temperature rise on the internal duct surface of duct type A should not exceed 140

oC mean or 180

oC maximum. The steel duct

satisfies the first of these recommendations, as steel is deemed to be non-combustible. The thicknesses of FirePro/FP-900 board and Rockwool insulation required for the various fire resistance ratings are given in Table 4




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Table 4. - Kitchen Extraction Ducts with Combustible Internal Linings

System

Fire resistance - minutes Kitchen extract duct


mm

Rockwool

mm x kg/m3

4K1 120 120 30 12 50 x 60

5K1 120 120 60 12 50 x 80

Note 1: - non-mandatory annex to BS 476: Part 24: 1987 required for kitchen extract duct

For projects where the insulation recommendations are not required, the un-insulated and partially insulated duct systems, as listed in Tables 2 and 3 for the relevant fire duration, can be used as a kitchen extract duct system for ducts A and B. Multiple Side-by-Side Ducts This system is for two or three adjacent steel ducts, independently supported, that have the same height. The protection system is installed around the ducts in the same way as for the 4-sided duct system except that the channel collars are fitted around the outside of the group of ducts rather than around the individual ducts. Also a vertical FirePro/FP-900 board is fitted between the steel ducts, fastened to the top and bottom FirePro/FP-900 boards with steel angles in the same manner as for the longitudinal corner joints. The maximum overall size of the steel ducts is 7500mm wide x 2500mm high. Two Tier Ducts This system is for two tier adjacent steel ducts that have the same width. The protection system is installed around the ducts in the same way as for the 4-sided duct system except that the channel collars are fitted around the outside of the group of ducts rather than around the individual ducts. Also a horizontal FirePro/FP-900 board is fitted between the steel ducts, fastened to the side FirePro/FP-900 boards with steel angles in the same manner as for the longitudinal corner joints. The maximum overall size of the steel ducts is 2000mm wide x 3000mm high. Vertical Ducts The construction of vertical ducts is the same as for the horizontal ducts. In order to support the duct system in the vertical orientation, steel sections are fastened to the steel duct, either along the two longer or shorter sides or on all four sides. The weight must be taken by the steel duct and not by the FirePro/FP-900 board. The steel sections either span across the opening in the concrete floor or form part of a cantilever bracket that is fastened to the building structure. If the distance between the floors is greater than 5m then intermediate supports must be fitted, e.g. cantilever bracket from adjacent fire rated wall. Also, to prevent buckling of the duct, the distance between supports must not exceed 8 times the smallest lateral dimension across the outside face of the steel duct. The weight of the duct system is taken by the building structure at




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each floor level. The stress limit within the steel supports is 15N/mm2 for fire exposures of up to

60 minutes, 10N/mm2 for fire exposures of up to 120 minutes, 8N/mm

2 for 180 minutes fire

resistance and 6N/mm2 for fire resistance periods up to 240 minutes.

The design of the penetration seal for vertical ducts through concrete floors is the same as for horizontal ducts through masonry/concrete walls. Access Panels The maximum opening size of the panels is 600mm x 450mm. The panels must not interrupt a cross joint or a stiffener. The access panel and frame fitted in the steel duct must be a proprietary steel panel assembly that has been shown by test to BS 476: Part 24: 1987 in a steel duct to be suitable for the required fire rating. Steel channel collars and longitudinal channels are fitted to the duct around the opening. They are fastened to the steel duct with M3.8 steel self-tapping screws at 200mm maximum centres. The access panel in the FirePro/FP-900 board is made with two layers of board, the inner being the same thickness as that protecting the steel duct and the outer being minimum 9mm thick. The boards are fastened to a steel frame of angles, 50mm x 50mm x 1.2mm thick, with M3.8 steel self-tapping screws at 200mm maximum centres. The angle frame is a close fit within the channel frame. The rock wool insulation is fitted to the panel within the angle frame. The access panel is fastened to the channel frame around the opening with M6 steel bolts, nuts and washers or with M5.5 steel self-tapping screws and washers at 200mm maximum centres. Flexible Connections All materials used for flexible connections must be non-combustible in terms of BS 476: Part 4 or 11, or a material of limited combustibility in terms of BS 476: Part 11, or Class 1 in terms of BS 476: Part 7. The flexible connection system must have been shown by test, to BS 476: Part 24: 1987 (ISO 6944: 1985) or equivalent, to be suitable for fire resistant steel duct constructions for the required duration and to be able to maintain the integrity of the steel duct. The steel duct must be supported adjacent to both sides of the flexible connection.




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Appendix A. Soben International FirePro/FP-900 Steel Duct System – Construction Drawings

Figure 1. Construction of FirePro/FP-900 steel duct system – nomenclature




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Figure 2. Cross sections through 4-sided duct system




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Figure 3. Cross section through 3, 2 & 1-sided duct systems




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Figure 4. Penetration seals




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Figure 5. Alternative hanger support and details of access panel




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Figure 6. Alternative board joint details

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