Presentation Rudolf Hensel GmbH and Audax-Keck GmbH

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2 Agenda Presentation Rudolf Hensel GmbH and Audax-Keck GmbH Why do we need Fire Protection? Why do we need to protect Steelwork against fire? Steel Fire Protection Systems Possibilities of Fire Protection Steel Fire Protection Systems Principle of Fire Protection Coatings Steel Fire Protection Systems Then and Today Steel Fire Protection Systems Improvement of Constructions Steel Fire Protection Systems What You can expect Steel Fire Protection Systems in the Future Where do we want to go? Fire Protection Systems for Wood and Concrete

3 Presentation Rudolf Hensel GmbH and Audax-Keck GmbH

4 Presentation Rudolf Hensel GmbH and Audax-Keck GmbH

5 Why do we need Fire Protection? A number of fundamental requirements of fire protection are specified in the Building Regulations which are different in any country

6 Why do we need Fire Protection? Means of escape Internal spread of flame to linings Structural Integrity of the building Fire compartmentation Access and facilities for emergency services Reduce the rising cost of insurance polices Protect capital investment Reduce the possible risk to the fire fighters

7 Why do we need to protect Steelwork against fire? Building Codes require that steel is protected to ensure loadbearing strength

8 Why do we need to protect Steelwork against fire? Building Codes require that steel is protected to ensure loadbearing strength Temperatures rises from 20 C to more than 1000 C

9 Why do we need to protect Steelwork against fire?

10 Possibilities of Fire Protection Fire Protection Active Fire Protection Passive Fire Protection Sprinkler Suppression Halogen Extinguishers Coverings Cementitious Systems Fire Protection Coating Systems Activation only in case of Fire: High Maintenance Costs Always active and alert: Low Maintenance Costs

11 Possibilities of Fire Protection Active Fire Protection Sprinkler Halogen Suppression Extinguishers Activation only in case of Fire: High Maintenance Costs

12 Possibilities of Fire Protection Passive Fire Protection Fire rated doors Barriers, Sealings Structural fire protection Coverings Cementitious Systems Fire Protection Coating Systems Always active and alert: Low Maintenance Costs

13 Possibilities of Fire Protection Passive Fire Protection Structural fire protection Coverings (Boards) Cementitious Systems Fire Protection Coating Systems Always active and alert: Low Maintenance Costs

14 Possibilities of Fire Protection Passive Fire Protection Structural fire protection Coverings (Boards) Cementitious Systems Fire Protection Coating Systems

15 Possibilities of Fire Protection Structural fire protection Coverings (Boards) Advantages Clean, dry installation Fire performance and finish all in one Up to 240 minutes fire performance

16 Possibilities of Fire Protection Structural fire protection Coverings (Boards) Disadvantages Hides the feature of the steel member No good on complex shapes Long application time Thickness at higher performance can be an issue Weight can be an issue with dense boards

17 Possibilities of Fire Protection Passive Fire Protection Structural fire protection Coverings (Boards) Cementitious Systems Fire Protection Coating Systems

18 Possibilities of Fire Protection Structural fire protection Cementitious Systems Advantages Low Cost Thermal and accoustic insulation Up to 240 minutes fire performance

19 Possibilities of Fire Protection Cementitious Systems Disadvantages Very messy application Easily damaged (no impact resistance) Space required for given protection Wire reinforcement might be required Difficult to ensure uniform thickness

20 Possibilities of Fire Protection Passive Fire Protection Structural fire protection Coverings (Boards) Cementitious Systems Fire Protection Coating Systems

21 Possibilities of Fire Protection Coating Systems Advantages Ideal where the exposed profile of the steel is a feature of the building design Only system suitable for castellated and cellular beams where the openings are used for services Light weight compared to other systems

22 Possibilities of Fire Protection Coating Systems Advantages Thin film systems reduces the amount of space used Up to 10 times faster to apply than boarding systems Decorative topseals available Fibre free, no dust Easy to clean and maintain

23 Possibilities of Fire Protection Coating Systems Disadvantages Quality checks required Primer compatibility checks required Drying times Masking may be required to surrounding areas Skilled labour application for best results

24 Possibilities of Fire Protection Coating Systems Intumescent coatings are the most efficient coatings for 30, 60, 90 and 120 minutes retardation time. Now also successfully tested up to 180 minutes!

25 Principle of Fire Protection Coatings A Fire Protection Coating is a perfect fire protection for simple steel constructions as well as for complex modern steel constructions. The fire protection system reacts to the heat and produces a temperature insulating char protects the steel construction against critical temperatures saves valuable time for evacuation and firefighting

26 Principle of Fire Protection Coatings Intumescent Coatings Principle (lat. intumescere = to foam) Temperature Formation of a voluminous insulating protective layer by developing a carbon-rich foam and a concurrent expansion. General composition of an intumescent coating: Heat Oxygen Combustible gases Pyrolyse Heat Decomposition products Smoke Protective layer 1) Carbon source Decomposition 2) Acid donor 3) Blowing agent Expansion Clariant Produkte DE GmbH

27 Rudolf Hensel GmbH Principle of Fire Protection Coatings * Melting of the binder * Acid release by thermolysis of the acid donor (NH PO ) 4 3 n >300 C -n NH 3 (HPO ) 3 n * Reaction of acid with the polyalkohol >550 C -n H O 2 2 n 4 P O 4 10 (HPO ) 3 n + C x(h 2O) m "C" x + (HPO ) H O 3 n m 2 * Thermolysis of the foaming agent H 2 N N N N NH 2 O NH 2 3 N 2 + H 2 O NH 2 * Development of a compact inorganic foam structure 2 HPO 3 + TiO 2 TiP 2 O 7 + H 2 O

28 Principle of Fire Protection Coatings The intumescent foam attains a thickness 10 to 100 times that of the originally applied coating and insulates the substrate material by its low thermal conductivity.

29 Principle of Fire Protection Coatings Intumescent Coating Flame Retardant Paint Fire Resistant Coating Public / Residential Fields Installations Fields Construction Fields Industrial Fields Timber and/or Textile in Hotels Restaurants Doors Roofs / Sealing Residential Houses Cable trees and ducts Sealants Airports Hotels Hospitals Sky Scrapers Shopping Centers Nuclear Power Plants LCD / PDP Plants Industrial Plants Off-Shore Plants Fuel Storage Tanks Spread of Flame / Flame Retardant Tests Cellulosic Fire Tests Hydrocarbon Fire Tests

30 Temperature Principle of Fire Protection Coatings Fire Protection Coatings are efficient in the phase of a fully developed fire! Flame Retardant Paints are efficient in the phase of fire development! fully developed fire fire ongoing fire development 0 fire start 0 minutes hrs flash-over time risks ignition source flammability flame spread heat release full scale fire smoke, irritant, toxicity, corrosivity

31 Temperature Principle of Fire Protection Coatings Hydrocarbon Fire Curve Cellulosic Fire Curve Time ISO 834 UL 1709

32 Temperature [ C] Principle of Fire Protection Coatings Uniform-temperature-time-curve acc. to ISO R 834 Steel temperature at HpA = 200 without IC Steel temperature with IC Hensel Time [min] ISO 834 Fire-resistance tests - Elements of building constructions ASTM E-119 / UL263 Standard test methods for fire tests of building constructions and materials BS 476 Part 20 and 21 Fire tests on building materials and structures EN Fire resistance tests - Part 1: General requirements EN Tests methods for determining the contribution to the fire resistance of structural embers - Part 8: Reactive Coatings for steel members

33 Principle of Fire Protection Coatings Primer Primer + Intumescent Coating Primer + Intumescent Coating + Top Coat sand-blast cleaned steel surface accord to Sa 2,5 1 st layer Primer protection against corrosion 2 nd layer Intumescent Coating protection against fire 3 rd layer Top Coat protection against environmental influences

34 Steel Fire Protection Systems Then and Today Source: Rudolf Hensel GmbH Source: Rudolf Hensel GmbH R30 SB indoor use DFT 2-4 mm 1970 Source: Rudolf Hensel GmbH Werner J. Hannappel, Tomas Riehle R30 SB less solvents DFT 1-2 mm 1980 R60 WB/SB weather-resistant DFT 1-3 mm 1990 R90 WB/SB weather-resistant outdoor use R90 DFT 2-4 mm Deko Paint VOC Green Building LEED / DGNB

35 Steel Fire Protection Systems Then and Today > 1970 Architects recognize benefits of fire protection paints for steel IC solvent based For open profiles Fire resistance classification R30 High film thicknesses (2-3mm) Mainly for indoor use > 1990 Launch of water-based IC Fire resistance classification up to 60 Minutes (R60) Indoor use without top coat More efficient formulas due to a new generation of raw materials: improved weather-resistance low coverage rates > 1980 Realisation of huge construction projects with steel-, anti-corrosion- and fire protection coatings Launch of single-layer systems with less solvent contents IC still mainly solvent based Improved colour designs due to top coat developments > 2000 First approval for a solvent-based IC with fire resistance classification R90 First approval for water-based IC Construction projects with high surface requirements (smooth or textured) Decorative steel fire protection systems become more important

36 Steel Fire Protection Systems Then and Today > 2010 R90 steel fire protection systems are more attractive than plaster or panels Film thicknesses of 2 4 mm for R90/R120 (for plaster or panels 20 mm are necessary) DekoPaint-Standard (2010) requires very low VOC-emissions Growing demand of Green Building, sustainable building and LEED

37 Steel Fire Protection Systems Then and Today Modern steel fire protection systems provide maintenance-free long-term protection protect against corrosion are aesthetic due to low film thicknesses provide long fire resistance up to three hours (R180) protect filigree constructions too are cost-effective meet relevant standards worldwide are sustainable

38 Improvement of Constructions Common tasks Optical attractive design Weight- and cost-optimized construction High-quality surfaces Result Visible circular and rectangular hollow sections Source: Rudolf Hensel Thin-walled steel sections Inappropriate colour shades Challenges Fire protection not duly taken into consideration in the planning stage

39 Improvement of Constructions Background Heat conductivity of open profiles is better than heat conductivity of circular and rectangular hollow sections Partially no approvals for circular and rectangular hollow sections Higher film thicknesses for filigree profiles required Consequences for fire protection High film thicknesses for hollow sections required Additional work steps to reach the necessary film thickness Additional costs Big influence on the optical appearance of the steel sections Conclusion Consideration of fire protection in the earliest planning stage will lead to cost-effective solutions combined with a high level of fire safety and surface appearance.

40 Improvement of Constructions Thermal absorption of different steel profiles Massive profiles heat up slowly Critical temperature is reached slowly Low film thickness of fire protection coating is sufficient Filigree profiles heat up quickly Critical temperature is reached quickly High film thickness of fire protection coating is necessary

41 Improvement of Constructions Section Factor (High) Hp/(Low) A Section Factor (Low) Hp/(High) A Low fire resistance Greater protection required High film thickness High fire resistance Less protection required Low film thickness

42 Improvement of Constructions Mathematical formulas for the calculation of the section factor Hp/A

43 Improvement of Constructions brushed rolled sprayed

44 Steel Fire Protection Systems in the Future Where do we want to go? Modern steel fire protection systems for sustainable building Water-based Free from plasticizers Free from Substances of Very High Concern (SVHCs) 1),3) Free from CMR-Substances according to CMR- Guidelines 2),3) Free from halogenes 3) Source: Rudolf Hensel GmbH fotolia 1) Acc. to REACH-Regulation (EG) No. 1907/2006 2) BAuA (consisting of CLP-Regulation 1272/EG/2008 and TRGS 905/906) 3) Small amount > 0,1 % contained

45 Steel Fire Protection Systems in the Future Where do we want to go? Modern steel fire protection systems for sustainable building Green Building-Certifications: LEED, BREEAM, DGNB PCF (Product Carbon Footprinting) CO 2 -Footprinting 4) acc. to ISO-Norm 14040/44 Recycling: Clearance Certificate Source: Rudolf Hensel GmbH fotolia 4) CO 2 -Footprinting simplified for CO 2e -Footprinting

46 Sustainable Fire Protection Systems VOC Content vs. VOC Emission VOC Content VOC Emission product-specific property application-specific property

47 Sustainable Fire Protection Systems Practical example of VOC in a project of 1,000 m² Primer sb: 31 % VOC (m/m) Primer sb Primer wb Primer wb: 4 % VOC (m/m) m VOC/Project [kg]: 59 8 DFT 60 µm: 190 g/m² V (Solid) IC1-3: 70 % IC1: 350 VOC g/ltr IC2: 50 VOC g/ltr IC3: 5 VOC g/ltr DFT [µm] WFT [µm] Wet amount [Ltr/m²] IC1 VOC [g/m²] IC2 VOC [g/m²] IC3 VOC [g/m²] IC1 VOC Project [kg] IC2 VOC Project [kg] IC3 VOC Project [kg] , , ,

48 Source: Emission Sustainable Fire Protection Systems VOC Emission Air Change Absorption and Analysis 3 days (Renovation) 14 days 28 days Time Source: Eurofins

49 Sustainable Fire Protection Systems Labels Minimum legal requirements Quality labels Environmental label Building Labels Emissionsge prüftes Bauprodukt nach DIBt- Grundsätzen Z-.

50 Sustainable Fire Protection Systems Environmental Product Declaration The Life Cycle Inventory (LCI) includes information regarding resource consumption, e.g. energy, water and renewable resources as well as information regarding emissions in air, water and soil. The Life Cycle Impact Assessment (LCIA) is based on the results of the LCI and specifies the concrete environmental effects. These are: Greenhouse effect Destruction of the ozone layer in the stratosphere Acidification of water and soil Eutrophication Formation of photochemical oxidants Exhaustion of fossil energy resources Exhaustion of mineral resources Source: Furthermore additional information with respect to environmental issues (e.g. threats and risks for human health) and/or information regarding function and performance of a product can be given. Source: Technisches Komitee ISO/TC 207 Environmental Management, ISO

51 Sustainable Fire Protection Systems Environmental Product Declaration (EPD) Source:

52 Sustainable Fire Protection Systems Reference HUGO BOSS AG, Metzingen with HENSOTHERM 420 KS A new administration building for Hugo Boss AG has been build on the campus of the headquarters in Metzingen. With this building the overall concept developed in the year 2000 has been continued. The construction site started in February In May 2013 the building was handed over to the user. Certified according to DGNB Gold Standard IWS Award 2013

53 Sustainable Fire Protection Systems

54 Fire Protection Systems for wood Primer HOLZGRUND AQ or HOLZGRUND SB Intumescent Coating HENSOTHERM 2 KS AUSSEN Top Coat HENSOTOP 84 AUSSEN

55 Fire Protection Systems for concrete Underground car park with HENSOTHERM 820 KS Preparation of the surface HENSOMASTIK B 3000

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58 Rudolf Hensel GmbH Lack- und Farbenfabrik Lauenburger Landstraße Börnsen Phone Audax-Keck GmbH Weiherstraße Calw Phone