1XR Application Instructions
 

Application of Type 1XR^TM shall be performed by qualified Contactors. Contractors shall use proper spray equipment and experienced personnel to complete the installation in accordance with the job’s specifications and Southwest Fireproofing’s application instructions. Whenever Southwest Fireproofing’s application instructions differ from the job’s specifications, contractor shall resolve any discrepancy with the project engineer.

1.2 FIREPROOFING

Fireproofing shall be Southwest Fireproofing Type 1XR^TM as specified in the contract documents.

Type 1XR^TM shall be delivered to the job site in original unopened packages, and it shall be stored off the ground in a dry area and protected from the weather and job site damage or contamination by adequate covering.

Water to be mixed with Type 1XR^TM shall be clean, potable and free from chemical contamination or visible organic material. Water temperature shall not be above 75⁰F.

1.4 REINFORCING MATERIALS

Reinforcing materials when specified, anchoring accessories, bond coat and primers for structural steel members shall conform to the requirements provided in the Underwriters Laboratories Fire Resistance Directory, latest edition. Any other products shall be evaluated and improved, in writing, by the specifier prior to commencement of the work.

Reinforcing materials, anchoring studs and primers shall be as specified in the following paragraphs.

1.4.1 METAL LATH

Metal lath shall be 3.4 pounds per square yard galvanized expanded steel lath, conforming to ASTM

C-847 specification.

1.4.2 MESH

Reinforcing mesh shall be No. 20 SWG galvanized steel wire twisted to form 1-inch hexagons. Wire shall conform to ASTM A-641 Part 3 specification for galvanized steel wire.

1.4.3 CORNERS

For interior work, corner beads shall be of galvanized expanded metal lath with metal wings of 2-7/8 inches and solid metal nose similar to Inryco/Milcor No. 1 Expansion Corner Bead or No. 10 Bull Nose Corner Bead. They shall conform to ASTM A-641 Part 3 specification for galvanized steel wire for lathing and furring.

For exterior applications or other areas subject to high humidity, edges shall be chamfered. As an alternate, corner beads as described above may be used.

1.4.4 STUDS

Anchoring studs shall be 1 inch long with self-locking washers.

All surfaces to receive fireproofing shall be dry and free of dirt, dust, oil or grease, rust scale, loose or flaking paint or other contaminants which could negatively affect adhesion. Type 1XR^TM may be applied directly over clean bare steel or clean galvanized steel substrates.

Type 1XR^TM may also be applied over approved primers. Surface preparation for primer to be in accordance with instructions from the primer manufacturer.

2.3 GALVANIZED STEEL

Galvanized steel shall be clean of all oil, grease, etc. by washing with trisodium phosphate and rinsing with clear water.

Requirements for metal reinforcement to be applied to the substrate prior to applying Type 1XR^TM vary and depend on the purpose of the reinforcement. The four basic uses of reinforcement are as follows.

• To meet Underwriters Laboratories Inc. Design requirements for mechanical breaks on painted steel shapes.
• To selectively reinforce some areas of "contour" applications obtained by direct steel fireproofing applications.
• To provide a "boxed" shape to beams and columns rather than the "contour" shape.
• To provide attachment and reinforcement for vessels, pipes, flat plates and other shapes.

3.2 MECHANICAL BREAKS

For "contour" applications to painted or primed beams and columns, Type 1XR^TM requires metal lath mechanical breaks and bond strength measurements as specified by Underwriters Laboratories Inc. Requirements are contained in the introductory section of the Fire Resistance Directory under the heading "Coating Materials". These requirements apply to painted or similarly coated shapes exceeding web depths of 16 inches and flange widths of 12 inches for beams and 16 inches for columns.

Metal lath is to be applied for mechanical breaks as required by Underwriters Laboratories Inc.

3.3 CONTOUR REINFORCEMENT

Galvanized steel wire mesh is required for reinforcement of Type 1XR^TM in critical areas when applied to the contour of steel shapes in many cases. The requirements vary by product.

For Type 1XR^TM metal mesh is required on all beam or column flanges larger that 18 inches and on all web members exceeding 18 inches regardless of whether or not they are painted.

The galvanized steel mesh as described in Section 1.4.2 above is to be installed on column flanges and beam bottom flanges by first cutting the mesh 4 inches wider than the flange and then bending 2 inches over each flange towards the web. A metal brake is to be used to make the bends. The mesh is to be secured in place with galvanized metal furring clips at 12 inch spacing.

Mesh is to be installed on web surfaces by use of anchoring studs (see Section 1.4.4) placed 24 inches on center.

3.4 BOX REINFORCEMENT

For "box" application to columns and beams having Type 1XR^TM applied to both flanges, use 3.4 pounds per square yard lath (as describe in Section 1.4.1) applied as follows.

Bend lath sharply (use metal brake) to closely encase the structural steel shape. Lath to be overlapped 1 inch and tied with No. 16 gauge galvanized wire, 14 inches on center.

On beams and columns, 18 inches or deeper, use supplemental cross supports, 18 inches on center. (Cross supports prevent lath from buckling when Type 1XR^TM is applied.) Cross supports to be No. 16 gauge metal, wedged between flanges. Tie lath to cross support using No. 16 gauge galvanized wire. In lieu of cross supports, tie No. 6 SWG galvanized wire around the member after the metal lath has been installed. Then tie metal lath to support wire with No. 16 galvanized wire.

Where corner beads are used, attach to lath with No. 16 gauge galvanized wire on either side of corner, 18 inches on center. Corner beads to be positioned to extend from the lath a distance equal to the required thickness of the fireproofing. Use the bead as a guide for the fireproofing thickness.

As a preferred alternative to use of beads, chamfer edges. Chamfer clips to be carbon or galvanized steel, 1/16 inch thick (minimum) and tack welded 18 inches on center.

3.4.2 APPLIED TO ONE FLANGE

For "Box" application (beams not having Type 1XR^TM applied to top flange), use 3.4 pounds per square yard lath per Section 1.4.1 installed as follows.

Blend lath sharply around bottom flange and attach to underside of top flange by anchoring studs (or approved equal) 18 inches on center.

For steel that will be exposed to weather, angle lath in to form sloped surfaces for water runoff. Use metal cross supports in accordance with Section 4.1.

3.5 VESSEL SKIRTS

Type 1XR^TM requires wire mesh reinforcing over the entire area of large flat or curved surfaces. Vessels, vessel skirts and pipes six inch diameter and larger are examples of such surfaces.

For vessel skirts when surface operating temperature will be less than 110⁰F, use 2"x 2" x 14 gauge galvanized steel mesh.

Attach mesh over the entire surface by use of anchoring studs (Section 1.4.4) 24 inches on center. Mesh shall be uniformly taut and tied. Mesh shall be positioned at midpoint of thickness of the Type 1XR^TM to be applied.

Where welding is not possible or the substrate cannot be penetrated, mesh shall be anchored using epoxy adhesive-backed studs and washers. The use of concrete reinforcing chairs placed around the circumference on 24 inch centers, attached by welding or wired to pre-installed lugs may also be used.

Unless directed otherwise by bid package/drawings or owner’s engineer, anchor bolts on vessel skirts shall be meshed and protected with Type 1XR^TM.

For surfaces with operating temperature between 110⁰F and 400⁰F, insulation board is to be attached prior to placement of mesh. The insulation board should conform to either ASTM C-612-77 for Mineral Fiber Block and Board Thermal Insulation or ASTM C-656-79a Structural Insulation Board, Calcium Silicate. The board should be rated for maximum temperatures expected.

Use insulation board with a minimum thickness of 1 inch. For temperatures above 200⁰F, increase the thickness of board by ½ inch for each 100⁰F of additional temperature expected. Attach boards with studs either welded or Ram-set. Boards should be tied to form a continuous uniform curved surface.

If boards will absorb water, apply ½ inch of Type 1XR^TM and allow to set. Then apply a coat of Weld-Crete manufactured by Larsen Products Corp., at the rate of 150 square feet per gallon. Finish applying the Type 1XR^TM to the required depth. Apply a curing agent, or wet cure as specified.

Use only fresh Type 1XR^TM dry mix from previously unopened packages stored under proper conditions. Partially set, frozen or lumpy material shall not be used.

Type 1XR^TM shall be mixed in mechanical mixer with paddle or ribbon type blades. Mixer shall be clean and free of all previously used and set materials. Normally Type 1XR^TM will be mixed in 2 bag batches.

4.2 WATER

Add water to mixer using approximately 8 gallons of water per 50 pound bag of Type 1XR^TM. Water shall be of drinkable quality and free of impurities that will effect the "set" of Type 1XR^TM. Water temperature shall not be above 75⁰F.

The amount of water required depends on equipment used, length of hose and ambient temperature. The exact quantity of water within the above range should be adjusted so that the wet densities at mixer discharge and nozzle are achieved.

4.3 MIX TIME

With mixer in operation add Type 1XR^TM and mix two to five minutes to a thick pumpable consistency.

4.4 WET DENSITY

Wet density of Type 1XR^TM at the mixer discharge shall not be less than 35 or more than 45 pounds per cubic foot (see Section 8.0, Field Sampling and Testing).

The contractor shall inspect and accept all surfaces prior to applying Type 1XR^TM.

5.2 SURFACE CONDITION

Surfaces shall be dry and free of dirt, dust, oil, grease, rust, scale and loose or flaking paint prior to applying Type 1XR^TM. Type 1XR^TM shall not be applied to metals, primers or paints which are not compatible with Portland cement, or to high gloss paints.

5.3 SPRAYING

Spray-apply Type 1XR^TM with machine utilizing a progressive cavity type pump equipped with an air compressor capable of delivering 9 cu. ft. per minute of air with 80 lbs. per square inch nozzle pressure. Equipment must be capable of meeting nozzle wet density requirements. See Sections 5.4 and 8.0.

5.3.1 PUMP LOCATION

Locate pump as close as practicable to the point of application to minimize length of hose required.

5.3.2 FLUSHING

Drain all water from the hose and attach it to the pump. Leave the spray nozzle removed from the hose, pump about 2 gallons of water through the hose followed immediately by the Type 1XR^TM.

5.3.3 SPRAY PATTERN

When a uniform consistency mix reaches the end of the hose, attach the spray nozzle. Establish a flow through the nozzle and adjust the air stem and air pressure to achieve the desired spray pattern.

5.3.4 BLOCKAGE

If a blockage occurs, run the pump in reverse until the hose pressure reaches zero before attempting to clear the obstruction. After the obstruction has been cleared, start the pump and reestablish flow. Pump all of each batch from the pump hopper before dumping a new batch from mixer.

5.4 NOZZLE DENSITY

Wet density at the nozzle for Type 1XR^TM shall not be less than 62 or more than 75 pounds per cu. foot.

5.5 THICKNESS

Spray-apply Type 1XR^TM in as many passes as necessary to conform to total required thickness (per fire rating specified). Total depth of Type 1XR^TM for each pass may be from 3/4 to 1-1/2 inches. Thickness applied per pass will depend upon consistency of Type 1XR^TM and the condition and orientation of the substrate.

When applying to overhead surfaces, i.e., beams, the total build-up each pass shall be less than 1 inch.

5.6 MULTIPLE PASS ADHESION

Allow 30 minutes or longer for Type 1XR^TM to set before subsequent passes. In all instances, the surface of Type 1XR^TM which has been previously applied must be wet prior to applying Type 1XR^TM.

For successive applications of Type 1XR^TM WITHIN 5 days of previously applied Type 1XR^TM, examine the surface of previously applied Type 1XR^TM. If the surface is wet, i.e., obviously wet to the touch, additional Type 1XR^TM can be applied directly to previously applied material. However, if surface is not wet, then thoroughly wet surface before applying additional Type 1XR^TM.

For successive applications of Type 1 XR^TM AFTER 5 days of previously applied Type 1XR^TM, examine the surface of the previously applied material. If it is wet, apply a concrete bonding agent Weld-Crete Acrylic Admix 101 by Larsen Products Corp. (or approved equal), before applying additional Type 1XR^TM. However, if surface is not wet, thoroughly wet surface and then apply concrete bonding agent before applying additional Type 1XR^TM.

5.7 TROWELLING

For finish trowelling, trowelling shall begin as soon as possible after last pass. Avoid overworking or excessive trowelling to prevent separation of materials and subsequent cracking.

CAUTION: Type 1XR^TM must be mixed, pumped and spray-applied prior to trowelling in order to achieve the required in-place densities.

Do not apply Type 1XR^TM if ambient air or steel temperature will be less than 40⁰F for the first 24 hours after application.

5.9 MINIMIZING SHRINK CRACKS

All Portland cement-based products, i.e., Gunite, Type 1XR^TM, etc., have an inherent tendency to form shrinkage cracks. This potential can be minimized by the use of curing compounds, certain topcoats, wet curing, or by wrapping freshly applied material in polyethylene.

Southwest Fireproofing recommends the use of concrete curing compounds (meeting ASTM C-309-81), topcoats, wrapping in polyethylene or water curing when steel will be exposed to weather and the following conditions exist during application.

Follow the manufacturer’s curing compound or topcoat data sheet for application instructions. To be effective, curing compound or topcoat must be applied within 2 hours of fireproofing application.

To wet cure, apply water mist for seven days.

Type 1XR^TM may be top coated for the purpose(s) of providing a specific color; minimizing possibility of shrinkage cracks; or when a chemical that attacks Portland cement will frequently come in contact with Type 1XR^TM.

When top coating for curing purposes, apply Tnemec Series 6 Tneme-Cryl within 2 hours but no sooner than 30 minutes after applying Type 1XR^TM.

When top coating for coloring purposes, use Tnemec Series 6 Tneme-Cryl, Series 52 Tneme-Crete, Series 66 Hi-Build Epoxoline, Series 74 Endura-Shield or Series 156 or 157 Elastomeric Acrylic.

For resistance to chemicals that attack Portland cement, consult the coating manufacturer.

Butyl, polysulfide or silicone caulking shall be used to seal all joints where Type 1XR^TM stops. Such joints include: underside of top flange of beams where Type 1XR^TM is not applied to top flange, columns where Type 1XR^TM stops below highest column elevation, etc.

Prior to Type 1XR^TM setting, thickness measurements should be taken to insure that the proper thickness per bid package (specification) have been applied. Any measuring tool, marked in known increments may be used. Southwest Fireproofing recommends ASTM E-605-77 "Standard Test Methods for Thickness…" be used.

8.2 DENSITY

Applied material with cured densities within the range specified by Underwriters Laboratories Inc. for the fire resistive design being utilized is required to assure that Type 1XR^TM is properly applied. Therefore, Southwest Fireproofing requires a field testing and sampling program (AND) the completion of Daily Job Records (see Section 8.3). AS A MINIMUM, mixer and nozzle wet density tests shall be taken twice daily.

Wet density is to be determined at two process locations for control purposes and the results confirmed by dry density measurements. The following tests are required.

• Wet density from the mixer.
• Sprayed (wet) density from the nozzle.
• Air dried density – usually 30 to 60 days after application.

The methods for determining densities are described below. If variations beyond the limits as set out are encountered, the mixing and spraying operation should be shut down and corrections made. Contact a Southwest Fireproofing representative whenever variations are encountered and cannot be corrected.

8.2.1 EQUIPMENT REQUIRED

• Platform scale with a capacity of 25 lbs. in at least ¼ lb. increments.
• A container with known volume, preferably a 6 in. x 12 in. concrete test cylinder or a 10 qt. pail.
• Test cylinders, 3 in. x 6 in., to preserve samples.
• Test report form (See Section 8.3)
• Test cylinder labels.
• ½ inch steel rod.
• Mason’s trowel.

8.2.2 TEST PROCEDURE

Mixing should be in accordance with mixing instructions (See Section 4.0). Accurate water measurement should be noted and recorded on the Type 1XR^TM Daily Job Report Form. Some things to be aware of during mixing are:

• If material is not sufficiently mixed in a paddle or ribbon-type mixer, segregation of materials can occur and heavier densities than desired can result.
• Mixing for an extended period of time will cause the material to become too light and fluffy, producing low density.
• Too much water will cause separation of the cement from the lightweight aggregate.

Obviously, a combination of more than one of the above faulty mix procedures will result in compounding improper mixer density results.

8.2.2.2 MIXER WET DENSITY

Mixer wet density samples should be taken directly from the mixer or an adjacent hopper as soon after mixing as possible. Either a 10 qt. pail or a 6 in. x 12 in. cylinder mold should be used for mixer density measurements.

• Material should be put into the pail or cylinder in 3 approximately equal levels. After each layer of material is put into the cylinder or pail, the pail should be tapped several times around the outside by using a ½ in. steel rod or similar instrument.
• Using a mason’s trowel or similar instrument, smooth the top of the material making it level with the top of the container.
• Remove excess material from the sides and bottom of the container. Weigh the material, calculate and record the wet density on the Daily Job Report Form.
• Calculate the wet density by multiplying the weight (in pounds) of material in the filled container by the Conversion Factor. See Section 8.2.4 for Conversion Factors and Density Requirements.

8.2.2.3 NOZZLE WET DENSITY

Nozzle wet density is to be taken at the point of application. When taking nozzle wet density at the beginning of each day or shift, allow one batch of material to be pumped through the hose and nozzle. Later, nozzle densities can be taken as required.

Nozzle wet density should be obtained by pumping and spraying the material into a container in a circuitous motion around the inside of the container. The nozzle should be held about 12 in. from the bottom of the container and withdrawn as the container is being filled, trying to maintain about 12 in. distance from the material.

Density should be obtained by using the same pumping and air pressure as being used to apply Type 1XR^TM to the work surfaces.

After the container has been filled, tap the side of the container several times using a ½ in. steel rod or similar instrument. Smooth off the top of the material using a mason’s trowel or similar instrument and make it level with the top of the container.

Remove excess material from the sides and bottom of the container. Weigh, calculate and record the wet density on the Daily Job Report Form. (See Section 8.2.4.

Variables known to affect nozzle wet density are:

(a) Pump Speed will affect the pumping pressure, thereby affecting the nozzle density. The more the pressure, the denser the mix.

(b) Hose length also affects pumping pressure. A long run of hose and/or vertical elevation will increase pumping pressure, thereby increasing the density. If a long run of hose is necessary, a larger diameter hose may be required to reduce pumping pressure.

(c) Air Volume and Pressure used to atomize the mix at the nozzle has a great affect on sprayed wet density. At least 9 CFM of air at 80 psi are often used and may be required to achieve the required dry densities in some applications.

Obviously, a combination of more than one of the above variables could result in compounding improper nozzle wet density results.

Air dried density is determined by spraying material through the nozzle into the 3 in x 6 in. cylinders. These cylinders should be carefully filled to insure that air pockets are not entrapped in the samples. Normal care should be exercised in storing these cylinders to allow proper curing and hydration of cement. The air dried density is the reading when material "reaches equilibrium"; that is when weight loss stops because moisture is no longer being released. The point at which this occurs will vary depending on material density and curing temperatures. After about 30 days, weights of the samples should be recorded and then checked periodically thereafter until such time as there is no additional weight loss.

When the nozzle wet density is within specifications, the air dried density will be as specified.

8.2.4 DENSITY REQUIREMENTS

Density requirements, conversion factors and calculation are provided in the following table.

8.3 DAILY JOB RECORDS

Field Sampling and Testing (per Sections 8) shall be conducted at the start of each day and at 3 to 4 hour intervals thereafter during the day. Data shall be recorded in the table attached to these instructions.

Clean all surfaces to be repaired by brushing with a stiff brush. If paint, oils or other foreign materials cover the area to be patched, this must be removed by chipping until a clean surface, free of loose material is present. If the surface to be patched is ‘green" that is, less than three days old, then the application of similar materials can be made by lightly wetting the surface prior to application. For materials older than three days, the surface will be cleaned as above, then thoroughly wetted. An application of concrete bonding agent such as Weld-Crete acrylic Admix 101 as manufactured by Larsen Products Corp. should be applied to the cleaned surface and the patching material applied to this before the bonding agent dries. If the surface has dried, then it must be slightly wet just prior to bonding agent application.

9.2 APPLICATION

The Type 1XR^TM used for repairing must be the same as the base material, that is, Type 1XR^TM should be used to repair damaged Type 1XR^TM.

For small areas, 1 foot diameter or less, ½ inch deep, the materials may be hand mixed in a bucket by adding about 1/3 gallon of water to one gallon loose material. For larger areas use the same application procedures as for new work.

Water should be added to give consistency about the same as masonry mortar. This can then be hand applied to damaged area and trowelled. At the edges apply pressure to the trowel to bond the new materials to the old. If a thickness of over one inch is to be applied, it is best to make this in two applications. Let the first application set for one hour before applying second coat. The patched area should be kept moist for 72 hours, by either covering with burlap or occasionally wetting to prevent drying out.

Follow recognized safe construction practices.

Type 1XR^TM contains Portland cement, which may cause skin injury when freshly mixed. Avoid contact with skin where possible and wash exposed areas promptly with water.

Wear OSHA approved eye protection, dust mask and hand protection. If Type 1XR^TM gets into the eye, rinse immediately and repeatedly with water and get prompt medical attention.

Provide ventilation in areas to receive Type 1XR^TM during and 24 hours after application.

Type 1XR^TM Fireproofing is slippery when wet. The general contractor and applicator shall be responsible for posting appropriate cautionary "SLIPPERY WHEN WET" signs. Signs should be posted in all areas in contact with wet fireproofing material. Anti-slip surfaces should be used on working surfaces such as scaffolding.

Do not use the materials prior to obtaining, reading and understanding the Material Safety Data Sheet (MSDS) for each material.

END OF APPLICATION INSTRUCTIONS –Rev: February 28, 2005

THE INFORMATION PROVIDED IN THESE INSTRUCTIONS IS BASED ON DATA AND INFORMATION CONSIDERED TO BE TRUE AND ACCURATE AT THE TIME OF PUBLICATION. IT IS OFFERED FOR THE USERS INVESTIGATION AND VERIFICATION BUT WE DO NOT WARRANT THE RESULTS TO BE OBTAINED. SALE OF TYPE 1 PRODUCTS ARE SUBJECT TO THE TERMS AND CONDITIONS OF MATERIAL INVOICES.

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                       Last modified: 4/29/09