Caveat|

The testing and inspection procedures described herein for |.

TECHNICAL
Sprayed Fire-Reiistive Materials are provided solely as'guides -
for field inspection. Their use is purely voluntary. The-described~
procedures, do not ini any way determine the suitability or <2.
MANUAL 12-A
Appropriateness of any- application. The ‘Application of ttie pro:
: cedures, or compliance\ with the procedures; shall not-constitute Third Edition
“any warranty, expressed. or‘implied; of the’ pérformarice chardie-
. teristics of any sprayed fire“resistive material for any purpose.
« The’standards, guidelines and assemblies referred toiin the pro
. cedures are for teference oily, and shall not constitute’@ recom=*
Standard Practice for the
mendation for the use of any: such standard, guideline oror assem:
bl. oe Be i
Testing and Inspection
Permission isi 5 granted for:sections of this tnanwal to be incorporated
. into: contract specifications and documents provided that the author.
"of the contractspecifications and documefts accepts, complete:and

the reproduction of the suggested forms contained ini Appendix K

of this manual; the agency or individual utilizingthese forms...
assumes complete and total responsibility for their“appropriateness
and conformance fo contractct specifications.

No part ‘of his moncal may y be reproduced ini ) ony manner,

-.” stored in any type of retrieval system;'or- ‘transmitted in any
form, for any, purpose otter than those listed above, ‘withoutthe |"
express written consent of The Association of the.Wall and Ceil-
. ing Andusiries—Internatiorial- and the Foundation of the.Wall and-
Geling Industry. : i
of Field Applied Sprayed
the is: of wes ofttest equipment! found iin1 Appin Ci is provid:
al purposes only and has been compiled’ from all”.
ikncwn, avoilable information: The isting is'solely in alphabetical Fire-Resistive Materials;
order, made atnd charge and‘does: not constitute an eridorsement
or warranty, expressed. of inwpliéd, of thie suitability or appropriate:
| ness of any. products,manufactured by: thesé'firms for the intended”
an Annotated Guide
* testing purpose; not does this listing purport to be-all inclusive of the’) “
manufacturers of adliésive products available, which may be evalu-
ated for this purpose. Manuhicturers of adhésive products ‘are .
encouraged to contdct The Association ofthe Wall and Ceiling-
Industries International for ising, otat no > charge, in subsequent
printings of this manual.

© 1997 by i .
The Association of the Wall and Ceiting Industries— .
international Ve

_ Published by
The Association. of the Wall and Ceiling Industries—
International
803 West Broad Street, Suite 600, Falls Church, VA 22046
 Acknowledgement Foreword
The predecessor to this document, Inspection Procedure for Field
This manual was revised under the direction of Applied Sprayed Fire Protection Materials, first published in
Richard Eaton 1975 and last revised in 1990, provided invaluable guidance to
Chairman, AWCI Spray Fire-Resistive Materials Committee building owners, architects, code officials, testing agencies,
Conroy Brothers/Olympic Wall inspectors, contractors and others, by providing standard meth-
Minnetonka, Minnesota ods and practices for the field inspection of sprayed fire-resistive
materials.
AWCI gratefully acknowledges the contributions of the following
individuals who unselfishly donated their time, effort and knowl- Developed by the Spray Fire-Resistive Materials Committee of
edge in the preparation of this manual: The Association of the Wall and Ceiling Industries—International,
the procedure was the first to provide information critical to
Tom Cheatham establishing consistent field testing practices. Subsequently, sever-
LCR Contractors al standards for laboratory testing and field inspection of these
Dallas, Texas materials were published. Most notable were standards devel-
oped by the American Society of Testing and Materials (ASTM}
Don Cirilo Subcommittee E6.21. These standards are designated ASTM
Mandoval Vermiculite Products, Inc. E605, “Standard Test Methods for Thickness and Density of
Houston, Texas Sprayed Fire-Resistive Materials Applied to Structural Members,”
and ASTM E736, “Standard Test Method for Cohesion/Adhesion
Cornelius J. Coakley > of Sprayed Fire-Resistive Materials Applied to Structural Mem-
C. J. Coakley Company, Inc. bers.” The ASTM standards were developed within a consensus
Falls Church, Virginia process and represent a continual evolvement of physical and
analytical methods for the measurement of thickness, density and
John Danko bond strength.
Philip Kehoe
Isolatek International Corp. Additional standards and guidelines were provided by the Uni-
Stanhope, New Jersey form Building Code (UBC) in UBC Standard No. 7-6, “Thickness,
Density and Cohesion/ Adhesion Determination for Spray-
Ron Gerace Applied Fireproofing,” and by Underwriters Laboratories inc (UL)
William Ronca and Underwriters Laboratories of Canada’s (ULC) adoption of
W. R. Grace & Company tolerance criteria for sprayed fire-resistive material thicknesses.
Cambridge, Massachusetts These thickness tolerances have been adopted by all three United
States model code jurisdictions. UL and ULC thickness tolerance
John T. Whittle _ and fire-resistance-rating design-criteria are published in the UL
Niehaus Construction Services Fire Resistance Directory and in the ULC List of Equipment and
St. Louis, Missouri Materials, Volume 2 Building Construction.

Joseph A. Treadway As of the end of 1995, all three United States model code juris-
Daniel J. Kaiser dictions have adopted inspection requirements for SFRM that
Underwriters Laboratories, Inc. include testing for thickness, density and cohesion/adhesion.
Northbrook, IL These requirements are applicable to all projects using SFRM.

The members of the AWCI Spray Fire-Resistive Materials These new standards and acceptance criteria, along with the
Committee. evolution of knowledge gained through additional testing, engi-
neering research and practical field experience, have brought
And the similar contributions of those individuals before them who about the need to update the procedure. Concomitantly, informa-
brought order to the testing and inspection of spray applied fire- tion from these standards and acceptance criteria that may be
resistive materials through the development and publication of the useful to personnel involved in the testing of sprayed fire-resistive
earlier version of this publication.

ul ili
ae
 ‘Cana
perme iegadueriact Waletri?s

Contents
materials have been annotated and cross-referenced with the
updated procedure to produce this standard practice. Section Description
It is the responsibility of the concerned parties utilizing this stan- 1. Scope
dard practice to review and comply with the contract specifica- J Purpose
tions, applicable building code and the latest issue of the stan- 2 Description
dards cited therein, in determining the acceptability of spray 2. ] Limitation
applied fire-resistive material. 2. 2 Acceptance
General Information
This standard practice attempts to provide consistency in ] Standards

ARAPARADRA DDS WO WWWWY NNNNN

field testing methods and interpretation of the results. The 2 SFRM Classification
goal, as always, is to promote a higher level of quality and 3 Application Requirements
performance of sprayed fire-resistive materials, and to facili-
Jl Manufacturer's Instructions
4 Testing Requirement
tate the accurate, timely and cost-effective inspection thereof.
strate Conditions

RAR RAR OWON = 2 PNRRA— om

Inspection
Surface Conditions
Primers, Paints and Encapsulants
Primer, Paint and Encapsulant Bond Tests

=
Temperature
Ventilation
pection Procedure
Physical and Visual Tests
Acceptance
Inspection Firm
Qualifications
Testing Experience
Procedure
1 Design Criteria
1.1. Design Number
1.2 Adjustment Formula
2 Fire-Resistive Material
.2.1_ Container Labels
4.4.3 Schedule
4.4.4 Access
4.4.4.1 Inspection Conduct
445 Conduct of Testing
4.4.5.1 Noting Deficiencies
446 Test Reports
. Method of Tests
5.1 Random Sampling
Test Apparatus
Gr

Thickness Determination
WWD

Testing Hardened or Cured Material

hRWWWHWWWN>

Thickness Criteria
OO

Thickness Measurement
WW OW WWW

Timing
Thickness Maximum
ORUN—

Thickness Minimum
Failure
Thickness Measurement Averaging
Testing Frequency

iv ]
 5.3.4.1
5.3.4.2
Building Codes
Test for Floor (Deck) Sections
Standard Practice for the Testing
5.3.4.2.1
5.3.4.2.2
Test Report
Void Inspection and Inspection of Field Applied
5.3.4.3
5.3.5
Test for Beams, Joists, Trusses and Columns
Thickness Correction Sprayed Fire-Resistive Materials;
5.4 Density Determination
5.4.1 Density Criteria an Annotated Guide
5.4.2 Testing Frequency
5.4.3 Specimen Preparation
5.44 Measurement Method 1. Scope
5.4.4.1 Length and Width
5.4.4.2 Thickn ess 1.1 Purpose. The purpose of this standard practice is to provide
5.4.4.3. Removal field inspection procedures for the testing of sprayed fire-resistive
5.4.4.4 Drying materials (SFRM) applied to structural members and assemblies.
5.4.4.4.1 Microwave Ovens Used in Curing
5.4.4.5 Weight 1.2 Description. This standard practice provides methods by
5.4.4.6 Density Calculation
5.4.5 Displacement Method which a qualified testing agency can determine whether the
5.4.5.1 Test Procedure application of the SFRM is in accordance with the requirements
5.4.5.2 Volume Determination of the tested fire-rated assemblies referenced in applicable stan-
5.4.5.3 Density Calculation 7 dards and previously submitted for specific: project approval.
5.46 Density Correction Testing methods for obtaining physical characteristics of applied
5.4.6.1 Thickness Correction Formula SFRM are detailed in Sections 5, 6 and 7.
5.4.7 Test Report: Thickness and Density
5.5 Bond-Strength Determination 1.2.1 Limitation. This standard practice shall not be used to
(Adhesion/Cohesion) establish levels of performance. :
5.5.1 Waiver
5.5.2 Bond-Strength Criteria 1.2.2 Acceptance. The requirements of the contract specifications
5.5.3 Testing Frequency
and applicable building code shall govern the acceptability of
5.5.4 Test Apparatus
applied SFRM.
5.5.5 Methodology
5.5.5.1 Nondestructive Testing
5.5.6 Calculation
5.5.7 Test Report: Bond Strength 2. General Information
5.5.8 Bond-Strength Correction
5.5.8.1 Bonding Agents 2.1 Standards. This standard practice shall be applicable for the
. Condition of Finished Application testing of SFRM applied to structural members and assemblies as
6.1 Visual Inspection evaluated in accordance with standards recognized by the
6.2 Correction of Deficiencies applicable building code. These standards include American
Society for Testing and Materials £119, National Fire Protection
Patching
7.1 Patching Association NFPA 251, Underwriters Laboratories Inc. ANSI/UL
7.2 Patching Material 263, and Underwriters Laboratories of Canada ULC-S101-M.
Appendix A-Permanent Test Report Records and Illustrations | 2.2 SFRM Classification. This standard practice shall be applica-
Al Thickness of SFRM on Floor (Deck) Sections ble for the testing of SFRM identified as either “sprayed fiber” or
A.2 Thickness of SFRM on Beam
A3 Thickness of SFRM on Joists and Trusses “cementitious mixtures” bearing the UL or ULC label, as appro-
AA.l Thickness of SFRM on W-Shape Columns priate.
A42 Thickness of SFRM on Tube and Pipe Columns
Note: Cementitious mixtures typically consist of one or more
Appendix B-Alternate Test Method for Bond Strength (Cohe- binders, aggregates or fibers that are mixed with water fo form a
sion/Adhesion) of SFRM Exceeding 1,146 psf
slurry and conveyed through a hose fo a nozzle where com-
Appendix C-Resource Moterials and Test Apparatus pressed air is typically used fo disperse the material into a spray
Appendix D-Conversion Factors pattern. Spray fiber materials typically consist of one or more

2 3
binders, fibers or aggregates that are conveyed by low-pressure 3.2.1 Primers, Paints and Encapsulants. Unless specifically pro-
air through a hose to a nozzle where the material is mixed with hibited in the fire-resistance-rating design-criteria, SFRM shall be
atomized water and sprayed. Spraying and application instruc-
permitted to be applied to primed, painted or encapsulated wide
tions are printed on each bag of SFRM. flange steel shapes, in assemblies published in Ul’s Fire Resis-
tance Directory, provided
A. The beam flange width does not exceed 12 in.
2.3 Application Requirements. The SFRM application require-
(300 mm).
ments shall be based on testing conducted by a recognized
agency, in accordance with accepted standards, for an hourly B. The column flange width does not exceed 16 in.
(400 mm).
fire-resistance rating of a structural member or assembly. The
requirements detailed in the published reports include, but shall C. The beam or column web depth does not exceed
16 in. (400 mm).
not be limited to, the minimum thickness and dry density of the
D. Bond tests conducted in accordance with ASTM E736
applied SFRM, method of application, substrate surface condition
(including paints, primers and encapsulants), the use of bonding indicate a minimum average bond strength of 80 per-
adhesives, sealants (overcoats), reinforcing or other materials, cent and a minimum individual bond strength of 50 per-
and the need to seal the void at the intersection of fluted decks cent, when compared to the bond strength of the SFRM
and beams. These published requirements shall be met on the os applied to clean uncoated 1/8-in. (3-mm) thick steel
jobsite. plate. The average and minimum bond strength values
shall be determined based on a minimum of five bond
tests conducted in accordance with ASTM E736.
2.3.1 Manufacturer's Instruction. The manufacturer's published
instructions for the application of specific SFRM shall be fol-
3.2.1.1 Primer, Paint and Encapsulant Bond Tests. Bond tests to
lowed. These instructions include, but are not limited to, substrate
qualify a primer, paint or encapsulant per item 3.2.1.D shall be
temperatures and surface conditions, and SFRM handling, stor-
age, mixing, conveyance, method of application, curing and conducted only when the fire-resistive coating is applied to a
ventilation. primed, painted or encapsulated surface for which acceptable
bond-strength performance between these coatings and the fire-
2.4 Testing Requirement. SFRM shall be tested, as required by resistive material has not been measured. An acceptable bond-
ing agent approved by the SFRM manufacturer is allowed to be
the applicable building code and/or regulatory agency, when
applied fo structural members and assemblies including, but not
applied to a primed, painted or encapsulated surface to obtain
limited to, beams, joists, columns, metal decking, floor systems,
the minimum required bond strength where the bond strengths
wall assemblies, trusses, roof assemblies and other related struc-
are found to be below minimum acceptable values.
tural components.
As an alternative to the bond test conducted on control samples
applied to an uncoated stee! plate, the following method is
3. Substrate Conditions acceptable for use on unknown coatings in existing structures:
Sections of painted steel shall be coated with a bonding agent
3.1 Inspection. Substrate conditions shall be inspected and compatible with the sprayed material being used on the project.
The treated and untreated substrates shall be coated with SFRM,
deemed acceptable by the SFRM applicator and/or a represen-
tative of the manufacturer prior to the application of the SFRM.
cured and subjected to five bond tests each, in accordance with
ASTM E736. if the failure mode of the sections treated with the
3.2 Surface Conditions. Substrates to receive SFRM shall be free bonding agent is 100 percent cohesive in nature, it shall be
acceptable to use this bond test value as the control bond
of dirt, oil, grease, release agents, loose scale or paint, primers,
strength. The value obtained on the untreated painted section
paints and encapsulants other than those fire tested and classi-
shail be compared to the control value using the minimum 80
fied by a recognized testing agency, and any other condition
that may prevent adequate adhesion. Surface conditions not in percent average, 50 percent individual bond-strength accep-
tance-criteria.
compliance with the cited fire-resistance-rating design-criteria or
the SFRM manufacturer's specifications shall be reported to the
general contractor, and the owner or owner's representative, for If condition 3.2.1.D is not met, it shall be acceptable to provide a
correction. The acceptability of primed, painted or encapsulated
mechanical bond by wrapping the structural member with
steel shall be determined by consulting the design criteria cited expanded metal lath having a weight of not less than 1.7 lbs per
for the fire-rated assembly.
yd? (1.0 k/m’).
If any of the conditions specified in 3.2.1.A, 3.2.1.B or 3.2.1.C 4.2 Acceptance. The agency named in Section 4.3 shall be guid-
are not met, a mechanical break shall be provided. A mechani- ed by the instructions as specified in Sections 5, 6 and 7 of this
cal break shall be provided by mechanically fastening one or practice in determining the compliance of the SFRM application
more minimum 1.7 bs per yd? (1.0 k/m’) metal lath strips to the to the project specifications, See Section 1.2.2.
flange or web either by weld, screw or powder-actuated fasten-
ers, on maximum 12 in. (300 mm) centers, on each longitudinal 4.3 Inspection Firm. The testing of SFRM shall be conducted by
edge of the strip, so that the clear spans do not exceed the limits an accredited independent inspector and/or testing laboratory
established in conditions 3.2.1.A, 3.2.1.B or 3.2.1.C as appro- and/or agency acceptable to the owner or his representative
priate. No less than 25 percent of the width of the oversize and the SFRM applicator.
flange or web element shall be covered by the metal lath. No
strip of metal lath shall be less than 3-1/2 in. (89 mm) wide. 4,3.1 Qualifications. Personnel testing SFRM shall be familiar
with the application and use of these products, shall be thor-
As an olternative to metal lath, the mechanical break shall be oughly trained in the test methods and shall be experienced in
provided by the use of minimum No. 12-gauge steel studs with conducting field or laboratory testing procedures.
minimum No. 28-gauge galvanized steel disks if such a system is
described in a specific design (usually bottomless trench in an 4.3.2, Testing Experience. Personne! responsible for the execu-
electrified floor design) for the SFRM being applied. The studs tion of field inspection procedures and test reports shall have a
shall be welded to the oversize element in rows such that the minimum of three years of testing experience.
maximum clear span conforms to conditions 3.2.1.A, 3.2.1.8 or
3.2.1.C as appropriate. The spacing of studs along each row 4.4 Procedure. The procedures discussed in Sections 4.4.1
shall not exceed 24 in. (600 mm) and a minimum one stud per through 4.4.6 shall be established at a preconstruction meeting
256 in? (1,652 cm’) shall be provided. aitended by representatives of the owner, general contractor,
SFRM applicator and the testing agency and/or laboratory.
Where metal lath strips or steel studs and disks are used, an Applicable construction records, reports and information as
acceptable bond strength as described in item 3.2.1.D shall be described herein shall be furnished by the responsible party.
required. A bonding agent applied to the painted surface is an
acceptable method of obtaining the required minimum bond 4.4.1 Design Criteria. The owner or his representative (architect
strength where bond strength to a painted surface is found to be or engineer) and SFRM applicator shall make available to the
below minimum acceptable values. testing agency and/or laboratory a complete description of the
structural members and assemblies requiring SFRM. The descrip-
3.2.2 Temperature. A minimum ambient ond substrate tempera- tion shall have sufficient details, including UL, ULC or applicable
ture of 40°F (4.4°C) shall be maintained during and for a mini- testing agency fire-resistance-rating design-information, for the
mum of 24 hours after the application of the SFRM, unless other- purpose of conducting the field-inspection procedures.
wise recommended by the SFRM manufacturer.
4.4.1.1 Design Number. The UL or ULC fire-resistance-rating
3.2.3 Ventilation. Should natural ventilation not be sufficient, design-number, and date of issue of the appropriate UL or ULC
forced ventilation shall be introduced for curing. The SFRM man- publication shall be deemed to be adequate information for ref-
ufacturer shall be consulted for specific recommendations. erence in contracts, specifications, drawings, submittals and
reports. A copy of the published fire-resistonce designs from
other acceptable testing agencies shall be furnished.
4. Inspection Procedure
4.4.1.2 Adjustment Formula. Where a formula is used to adjust
4.1 Physical and Visual Tests. The following types of physical ” SFRM thickness applied to columns, beams or trusses, a complete
and visual tests are required by the fire-resistance-rating design- protection thickness schedule shall be provided.
criteria, contract specifications or applicable building code:
. Condition of substrates. 4.4.2 Fire-Resistive Material. The SFRM applicator shall make
T™™MONwD>

. Thickness of application. available to the owner, general contractor and testing agency
. Density in pounds per cubic foot {kgs per m’). and/or laboratory the name of the manufacturer and a product
. Bond strength-adhesion/cohesion (psf or KPA). description of the SFRM. that will be applied. The testing agency
Condition of finished application. and/or laboratory shall determine that the containers of SFRM to
Inspection of patching work. be applied are properly labeled by the manufacturer, and con-

7
firm that the SFRM is the material listed in the fire-resistance-rat-
ing design-criteria of the assembly to be protected, 5. Method of Tests
4.4.2.1 Container Labels. The SFRM container labels shall 5.1 Random Sampling. The tests described in this section shall
include the manufacturer and product name. The container shall be based on random samplings of specific structural members, or’
bear the UL, ULC or other recognized agency marking, which roof or floor deck, agreed upon by the owner, his representative
includes fire-resistance rating-information and (optional) the sur- or the testing agency.
face-burning characteristics of the product.
5.2 Test Apparatus. The following apparatus shall be used to
4.4.3 Schedule. Dates and schedules shall be mutually agreed determine the thickness and density of the SFRM:
upon for the application and testing of SFRM, the rendering and A. Steel Rule. Steel rule, tape or other measuring device
receipt of appropriate test reports and construction records, the graduated in at least 1/16-in. or 1-mm increments.
repair of cited deficiencies and final acceptance of the SFRM B. Thickness Gauge. A thickness gauge as approved by the
application. building authority having jurisdiction. See Figure 1
(page 10} for illustration.
4.4.4 Access. Testing agency and/or laboratory personnel shall C. Scales. Scales of sufficient capacity and sensitivity to
be permitted to enter the premises to observe the progress and weigh the test specimens to an accuracy of at least 0.1 g.
application of the SFRM, review the applicable construction D. Template. A rectangular template of known length and
records and perform their functions. width, having a minimum area of 48 in? (30,967 mm’);
the template shall be a minimum of 3 in. (76 mm) on
4.4.4,\ Inspection Conduct. The conduct of field inspection pro- one side.
cedures shall not interfere with the opplication of SFRM. Testing E. Knife. A knife or other suitable instrument capable of
agency and/or laboratory personnel shall not occupy scaffolding cutting completely through the SFRM to the substrate.
from which spraying operations are being conducted, ner shall ‘F Drying Oven. ’A drying oven or other device capable of
they attempt to supervise or in any other manner attempt to maintaining temperature and humidity conditions during
direct the activities of SFRM applicator employees during the the specimen curing cycle in accordance with the SFRM
handling, mixing, conveyance or application of SFRM. manufacturer's requirements.
. Lead Shot. Six 600 g bottles of lead shot size #8.*
4.4.5 Conduct of Testing. The independent testing agency

xm@
Gradvated cylinders. One 100 cc and one 250 cc
and/or laboratory shall perform the specified tests in accordance graduated cylinder. ;
with the methods described in Section 5 as soon after the appli- i. Funnel. One polypropylene funnel {top |.D. 150 mm;
cation of SFRM as practical. The SFRM applicator shall be imme- bottom 1.D. 28 mm).
diately advised of any deficiencies. J. Cylinder. One cylinder approximately 3 in. .D. and 4 in.
tall {a 400 ml smooth wall beaker will suffice).
4.4.5.1. Noting Deficiencies. The observed deficiency shall be K. Straightedge. One 6 in. (150 mm) or greater stiff
noted on the permanent test records similar to those found in straightedge to be used as a screed.
Appendix A. In standard industry practice, the testing agency L. Pan. One shallow, flat pan (approximately 6 in. (150
physically marks the area on the structural component where the mm] in diameter).
test results indicate that the minimum design criteria has not been
met. 5.3 Thickness Determination. Thickness of applied SFRM shall be
determined by an appropriate thickness gauge approved by the
4.4.6 Test Reports. A written report shall promptly be submitted building authority having jurisdiction, or as shown in Figure 1
to the owner or his representative {architect or engineer), general (page 10), and reported in accordance with Section 5.4.7.
contractor and SFRM applicator within one week after each floor
or 10,000 ff? (930 m) is tested, and at such time as the tested Description: The gauge shall consist of a disk fixed to a measur-
area is still readily available for correction of any deficiencies. ing rule with a needle probe attached toa sliding clip indicator.
The delivery of test reports shall be performed in a timely man- The disk shall be a minimum of 7/8-in. (22 mm) and a maxi-
ner to ensure that project construction schedules are met and that mum of 1-1/8-in. (29 mm} in diameter. The needle probe shall
the SFRM applicator has an adequate opportunity fo repair all be able to extend to penetrate the SFRM until the point reaches
deficiencies prior to the work of other trades (e.g., installation of the substrate. The thickness shall be read in 1/16-in. or 1-mm
ductwork, electrical and mechanical equipment, etc.) that would:
impair proper application. See Sections 5.4.7 and 5.5.7. * Ottawa silica sand and unexpanded polystyrene bead (designation “C bead”
may also be used in lieu of lead shot. ‘ene “gnenen

8 9
increments as shown by the position of the sliding clip indicator 5.3.2 Thickness Criteria. The required thickness of SFRM shall be
against the measuring rule. detailed in the UL, ULC or applicable testing agency fire-resis-
tance design or report for the fire-resistance rating of the struc-
Figure 1: Illustration of Gauge tural member or assembly. See Section 4.4.1.
GAUGE DISK 5.3.3 Thickness Measurement. One series of measurements shall
be taken on the deck, columns and beams in an area to be
inspected, unless more frequent measurements are required by
\ PIN the project specifications or applicable building code. See Sec-
cab arm
p ab st ts x tion 5.3.4 for testing frequency. Thickness measurements shall be
taken when the SFRM has stabilized and be recorded on perma-
uylul, Lh Mehopihr tsb ti’
nent records similar to the illustrations in Appendix A. Thickness
measurements shall be averaged in accordance with Section
SCALE 5.3.3.5 and reported in accordance with Sections 5.4.7.F and
5.5.7.
When the thickness gauge shown in Figure 1 is used, the follow-
ing procedure shall be employed: 5.3.3.1 Timing. Thickness measurements shall be taken after the
A. During the thickness measurement procedure, the gauge SFRM has stabilized. Contact the SFRM manufacturer for recom-
shall be positioned perpendicular to the substrate so that mendations.
the disk contacts the SFRM surfgce. Adequate pressure
shall be exerted (1) for the needle probe to penetrate Note: The physical characteristics of freshly applied SFRM vary.
the SFRM and make contact with the substrate and (2) During the initial set, some SFRMs expand while others shrink.
for the disk to register the average plane of the surface
of the SFRM. The gauge shall then be withdrawn to read 5.3.3.2 Thickness Maximum. For the purpose of averaging mea-
the thickness in 1/16-in. or 1-mm increments as shown surements, individual measured thicknesses that exceed the thick-
by the position of the sliding clip indicator against the ness specified in a fire-resistance-rating design-criteria by 1/4
measuring rule. in. (6 mm) or more shall be recorded as the thickness specified in
B. If there are excessive irregularities in the surface texture the design plus 1/4 in. (6 mm).
at a point of thickness measurement, the thickness gauge
shall be repositioned to the closest location representa- 5.3.3.3 Thickness Minimum. No individual measurement shall
tive of a more uniform surface. See Section 6.1. be more than 1/4 in. (6 mm) less, or more than 25 percent less,
than the thickness specified in the fire-resistance-rating design-
5.3.1 Testing Hardened or Cured Material. Where medium- and criteria. For thicknesses 1 in. (25 mm) or greater, the minimum
high-density SFRMs are too hard to test for thickness using a allowable individual thickness shall be the design thickness minus
standard procedure, it is recommended that thicknesses shall be 1/4 in. (6 mm). For thicknesses less than 1 in. (25 mm}, the min-
checked immediately after application and before curing. imum allowable individual thickness shall be the design thickness
minus 25 percent. ,
The applicator shall adjust the thickness of the freshly applied
SFRM to yield thickness after cure, in accordance with the SFRM 5.3.3.4 Failure. If an individual thickness measurement, or the
manufacturer's recommendations. average calculated measurement, of a structural member or roof
or floor deck in the randomly selected area or bay does not meet
" Where the product is cured and too hard to insert the thickness the design criteria for thickness average or minimum individual
gauge, small-diameter holes just large enough to accommodate thickness, then only that specific member or bay shall fail. The
the thickness-gauge pin shall be drilled perpendicular to the sur- remaining structural members or decks, in other areas or bays
face of the SFRM being measured. The thickness gauge shall then on the building elevation (floor), shall not be deemed to have
be inserted into these holes and thickness determined using the failed solely because the tested component has failed.
standard procedure. Holes shall be closed off immediately fol-
lowing the test using the same SFRM. If a structural member or roof or floor deck fails to meet the
design criteria for thickness average or minimum individual thick-
When metal lath is used in conjunction with bar joists, care shall ness, it shall be corrected and retested, and another similar com-
be taken to ensure that the needle probe contacts the substrate ponent in another randomly selected area on the same elevation
{bar joist). : (floor) shall also be tested.

10 4 11
5.3.3.5 Thickness Measurement Averaging. A single average been filled with SFRM unless they are not required to be filled by,
measurement shall be calculated from each series of individual the fire-resistance-rating design-criteria. Where the referenced
measurements of the structural members or roof or floor decks design allows the bridging or plugging of voids (in lieu of com-
tested. The calculated average thickness shall be equal to or pletely filling the voids}, the applicable building code shall be con-
greater than the thickness specified in the fire-resistance design- sulted to determine acceptability. Any observed deficiencies shall
criteria. Where a reduced thickness of SFRM on flange tips is be immediately reported to the SFRM applicator for correction.
specified in fire-resistance design-criteria, the thickness of SFRM Applications initially found to be deficient shall be corrected and
applied on the flange tips shall be averaged separately. The siri- reinspected,
gle average measurement calculated shall be reported as
required in Sections 5.4.7.F and 5.5.7.F. Thickness maximum 5.3.4.3 Test for Beams, Joists, Trusses and Columns. A series of
and minimum tolerances as detailed in Sections 5.3.3.2 and thickness measurements shall be conducted in a specific pattern
5.3.3.3 shall apply only to individual measurements. Acceptabili- as detailed herein. Certain UL and ULC fire-resistance-rating
ty of applied SFRM thickness shall not be determined by apply- design-criteria for beams and columns allow for a reduced thick-
ing these tolerances fo the thickness measurement average. ness of SFRM on flange tips when a greater thickness of SFRM is
applied to the contour of the beam, truss or column. These
5.3.4 Testing Frequency. Thickness measurements shall be made reduced flange tip: thicknesses shall be averaged apart from
on structural elements on a random basis in at least one bay per other sections of the beam, truss or column. Where a single
floor, or for each 10,000 f? (930 m?) of floor area, whichever thickness is required, the result shall be recorded as a single
provides the greatest number of tests, buP not to exceed one test average measurement. See Sections 5.3.3.5 and 5.4.7.F, Appen-
per 10,000 fi? (Example: 14,000 ff? would require two tests.). dix A-2 for beams, A-3 for joists and trusses, A-4 for columns.
Thickness measurements shall be conducted on each of the fol- A. Beams, Thickness measurements shall be made at nine
lowing structural elements present in each randomly selected locations around the beam at each end of a 12-in.
bay: one area of metal deck or concrete slab; one column; one (300-mm) length.
primary beam and one secondary beam; one joist; and one B. Joists and Trusses. Thickness measurements shall be
truss. ,
made at seven locations around the joist or truss at each
end of a 12-in. (300-mm) length.
5.3.4.1 Building Codes. Where the applicable building codes
govern testing frequency, the applicable building code shall be Certain UL and ULC fire-resistance-rating design-criteria
consulted for exact requirements. list the optional use of glass fiber mesh and/or metal
lath attached to one side of a bar joist to facilitate the
5.3.4.2 Test for Floor (Deck) Sections. A series of thickness mea- application of SFRM. When fiber mesh is utilized, the
surements shall be conducted in a specific pattern as detailed SFRM shall be sprayed only to the required thickness,
herein. The result shall be recorded as a single average mea- following the contour of both sides of the bar joist; the
surement. See Section 5.3.3.5; Appendix A-1; Section 5.4.7.F. gloss fiber mesh between the vertical members shall not
A. Flat Decks. In the preselected area, lay out a 12-in. be required to be sprayed. When metal lath is utilized,
(300-mm) square and take a minimum of four measure- the SFRM shall be sprayed to the required thickness, fol-
ments, symmetrically. lowing the contour on both sides of the bar joist; the
B. Fluted Decks. In the preselected area, lay out a 12-in. metal lath between the vertical members shall also be
{300-mm) square and take four random, symmetrical fully covered with SFRM but with no minimum thickness.
measurements within the square, including one each of Where use of glass fiber mesh and/or metal lath results
the following: valley, crest and sides and report as an in a protection thickness reduction in the applicable UL
average. or ULC fire-resistance design, the SFRM thickness shall
be applied to the entire joist, including all metal lath
5.3.4.2.1 Test Report. The test report shall clearly state the loca- and/or glass fiber mesh, at the fuil design thickness
tions of thickness measurements and the individual values mea- specified, ie. “sprayed solid.”
sured at each point. In certain fire-resistance-rating design-crite- C. W-Shape Columns. Thickness measurements shall be
tia, the required thicknesses of SFRM applied to the crest sides made at 12 locations around the column at each end of
- and valley of fluted deck vary and, if so, shall be averaged apart. a 12-in. (300-mm) length.
Consult the referenced design criteria. D. Tube and Pipe Columns. Thickness measurements shall be
made at a minimum of four locations around the column
5.3.4.2.2 Void Inspection. It shall be determined that the voids at each end of a 12-in. (300-mm) length.
created by the intersection of the fluted deck and the beam have
4

12 13
5.3.5 Thickness Correction. Thickness shall be corrected by 5.4.4.3 Removal. The specimen shall be removed from the sub-
applying additional SFRM at any location where the calculated strate by cutting with a knife or other suitable device along the
average thickness of the material is less than that required by the perimeter of the scored SFRM and through to the substrate. The
design; or where an individual measured thickness is more than knife shall be positioned perpendicular to the substrate during
1/4-in. {6 mm) less, or for thicknesses less than 1 in., more than the sampling procedure to ensure that the edges of the specimen
25 percent less, than the specified thickness required by the are square. The specimen shall be carefully removed without loss
design. of material.

5.4 Density Determination. Density of applied SFRM shall be 5.4.4.4 Drying. The specimen shall be conditioned by force dry-
determined and reported in accordance with Section 5.4.7. ing at a temperature of 109° +10°F (43° +6°C), and relative
humidity not greater than 60 percent, until constant weight is
5.4.1 Density Criteria, The minimum dry density at which the obtained. See Section 5.2.F and 5.4.4.5.
SFRM shall be applied to building elements shall be specified in
the individual fire-resistance-rating criteria or as otherwise 5,4.4.4.1 Microwave Ovens Used in Curing. Where SFRM man-
required by the specification or SFRM manufacturer and as fur- ufacturers permit the use of microwave ovens or other devices for
nished by the owner or his representative (architect or engineer). the curing of SFRM, the SFRM manufacturer shall be consulted
for specific recommendations.
A thickness to density correction formula is contained in certain
UL and ULC fire-resistance-rating criteria. The appropriate publi- 5.4.4.5 Weight. The constant weight shall be defined as succes-
cation or the SFRM manufacturer shall be consulted for ‘specific sive readings taken at eight-hour intervals differing by less than
information. See Sections 4.4.1 and 5.4.6. 1 percent, as determined on a suitable scale or weighing device
in appropriate U.S. or metric units. See Section 5.2.C.
5.4.2 Testing Frequency. The density of the applied SFRM shall be
determined by conducting tests on specimens on each floor, or in 5.4.4.6 Density Calculation. Density shall be calculated in accor-
each 10,000 f? (930 m7}, whichever provides the greatest num- dance with one of the following formulae:
ber of tests, but not fo exceed one test per 10,000 ff. (Example: A. D=W/Ixwxt
14,000 ff? would require two tests.) Density shall be determined Where: D = density, Ib/fP (or kg/m),
by conducting tests on specimens from each of the following ele- W = weight of the dried material, lb (or kg},
ments: a flat portion of the deck; a beam, either the bottom of the | = length of the specimen, ft {or m),
beam lower flange or the beam web; and a column, either the w = width of the specimen, ft (or m), and
column web or the outside of one of the column flanges. Alternate t = average thickness of the specimen, ft (or m).
elements shall be tested so that each element listed is equally test- B. D=Wx 1728/|Ixwxt
ed. See Section 5.3.4 for building code requirements. Where: D = density, Ib/f? (or kg/m’),
W = weight of dry material in Ibs,
5.4.3 Specimen Preparation. Density measurements shall be | = length of specimen in inches,
accomplished by selecting, measuring and preparing specimens w = width of specimen in inches, and
in accordance with either of the two methods described herein. t= average specimen thickness in inches.
Cc. D=Wx12/t
5.4.4 Measurement Method Where: D = density, lb/fP (or kg/m’),
W = weight of dry material in pounds, and
5.4.4.f Length and Width. The specimen to be tested shall be t = average specimen thickness in inches.
marked off by scoring the in-place SFRM on the building element
using a suitable template of known length and width. The speci- 5.4.5 Displacement Method. This method is recommended when
men area shall be not less than 48 in? (30,967 mm’); where pos- the SFRM specimen is difficult to remove from the substrate, such
sible, no dimension shall be less than 3 in. (76 mm). as when medium- or high-density or cured SFRM are installed.

5.4.4.2 Thickness. Thickness shall be determined within the area 5.4.5.1 Test Procedure. The sample shall be cut to a size to fit
of the specimen by the procedure described in Section 5.3. A inside the test cylinder, leaving at least 1/4 in. (6 mm) of space
minimum of 12 thickness measurements shall be made in a sym- between the sample and the cylinder on all sides. The sample
metrical pattern prior to removal of the SFRM from the substrate. shall be dried in an oven at a temperature of 109° +10°F (43°
The average value of these 12 measurements shall be deemed +6°C) and relative humidity not greater than 60 percent. Dry-
the thickness of the specimen.

14 15
ness shall be determined by a moisture-probe meter or by hav- 5.4.6. Density Correction. Where density measurements fail to
ing the sample reach a constant weight in accordance with Sec- meet the fire-resistance-rating design-criteria, the owner's repre-
tion 5.4.4.5. Once dry, the sample shall be weighed to the near- sentative (architect or engineer) shall determine remedial proce-
est 0.1 g. dures.

5.4.5.2 Volume Determination. With the shallow pan placed 5.4.6.1 Thickness Correction Formula. Certain UL and ULC
under the test cylinder, all of the lead shot shall be poured designs allow in-place SFRM density corrections by using a spe-
through the funnel into the test cylinder in a loose-fill manner. No cific thickness correction formula for densities below the listed
tapping or shaking of the cylinder shall take place. The lead shot minimum average and/or individual density requirement. The
shall completely fill the cylinder and overflow the cylinder slightly, appropriate publication or the SFRM manufacturer shall be con-
allowing the excess lead shot to fall into the shallow pan. The sulted for requirements of the specific design being tested.
straightedge shall be placed on and perpendicular to the top rim
of the test cylinder. In an even, back-and-forth manner, the 5.4.7 Test Report: Thickness and Density. The completed test
straightedge shall be drawn across the top rim of the cylinder to report shall contain all appropriate information, including the fol-
screed off the excess lead shot until the lead shot in the cylinder lowing:
is flush with the top rim of the cylinder. All the excess lead shot A. Project name and location.
that has fallen into the shallow pon shall be taken out of the pan B. Date of test and report.
and set aside. The cylinder now contains all of the lead shot C. Exact location on project where test was conducted or
needed for testing. specimen was removed.
D. Identification of the SFRM (product name, manufacturer
The lead shot from the cylinder shall be emptied into another and other pertinent information).
container. A small amount of lead shot shall be poured from the E. Description of specimen:
container back into the cylinder in a quantity sufficient to cover {1} Size of test specimen.
the bottom of the cylinder. The sample to be tested shall be (2) Any modification made to the SFRM specimen
placed onto the bed of lead shot in the center of the test cylinder. tested to obtain the reported values shall be noted.
Using the funnel, and with the shallow pan under the cylinder to (3) Description of any deviations from the test
collect the overflow of lead shot, all of the remaining lead shot method.
shall be loose-poured back into the cylinder. The lead shot shall F. Thickness. The overall average, and the maximum and
be screeded with the straightedge in the same manner as minimum thicknesses recorded in the measurement of
described previously. No shaking or tapping of the cylinder shall the tested structural members and assemblies {reduced
take place, and the lead shot in the cylinder shall be level with flange tip thickness shall be averaged separately),
the top rim of the cylinder. All the lead shot screeded off the top expressed in inches {or millimeters). A copy of the per-
of the cylinder shall be allowed to fall into the shallow pan. manent records, similar to Appendix A, shall be
attached fo this report.
To determine the volume of the sample, the lead shot shall be G. Density. The average, minimum and maximum density
poured from the shallow pan into the graduated cylinder. The values of the test specimens, expressed in pounds per
size of the graduated cylinder shall depend on the size of the cubic foot (or kilograms per cubic meter).
sample being tested. The graduated cylinder shafl not be shaken H. Appendices. All data not specifically required by this
or tapped, and the volume of lead shot shall be read in cubic section but useful for a better understanding of the test
centimeters. The vélume of the sample shall be equal fo the vol- report.
ume of lead shot in the graduated cylinder.
5.5 Bond-Strength Determination. Cohesion/adhesion (bond-
5.4.5.3. Density Calculation. The density of the specimen shall strength) determination shall be conducted as part of the field
be determined using the following method. It is suggested that testing of SFRM as required by contract specifications, the applic-
the reported density be the average of three measurements: able building code or where jobsite conditions dictate. Bond-
D =W x 62.43/ V strength determination is an acceptable method for determining
Where: D = density in lb/ft, the suitability of a questionable substrate (surface condition)
W = weight of sample in grams, scheduled to receive SFRM or if prior evaluation has not been
V = volume of sample in cubic centimeters. conducted, See Section 3.2.1.1. An accurate determination of
bond strength shall be accomplished only after the in-place
SFRM has cured. The SFRM manufacturer shall be contacted for
recommendations.

16 17
ai
Note: The test method described in this section has a maximum <———2%’___» Figure 2: lllustration
theoretical bond strength measurement capacity of 1,146 psf
when using the preferred 3 1/4 in. diameter cap and a 66 fb of Test Cap
force capacity fish hook scale. Project specifications for bond
strength of some SFRM can significantly exceed this value. An
alternate test method for determining bond strengths of these }———__
3%"
SFRM is described in Appendix B. %”

5.5.1 Waiver. Where jobsite conditions make testing difficult or

impossible, the building code authority having jurisdiction shall
be authorized to allow modified or alternative test procedures as
4
provided under the “Alternate Means of Evaluation” section of NAIL HOOK FOR WEIGHT
the appropriate building code.
not available, the specimen shall be no less than 4 in. x
5.5.2 Bond-Strength Criteria. in-place SFRM shall be subjected 12 in. (100 mm x 300 mm).
to an increasing force {either uniform or step-wise) at the rate of B. A quantity of adhesive sufficient to fill the cap {with the
11 lb (5 kg) per minute applied perpendicular to the surface via hook attached) shall be applied. The adhesive manufac-
a spring scale or series of weights until failure occurs, the turer's published mixing directions shall be followed.
required bond strength is attained or the capacity of the scale is C. The cap shall be immediately placed against the SFRM,
reached. Bond strength measurements of applied SFRM shall be in the center of the area to be tested. The cap shall be
noted in the test report. See Sections 3.2.1.D and 5.5.5. held in place until the adhesive has set sufficiently to
become self supporting. Excess adhesive shall be
5.5.3 Testing Frequency. The test shall be conducted on com- removed from around the cap before testing.
pletely cured material from areas adjacent fo test sections where D. After the adhesive becomes hard, force perpendicular to
thickness and density determinations have been made. One test the surface shall be applied slowly to the hook at a uni-
shall be conducted for beams, and one test for decks for each form rate and with deliberate care until failure occurs or
10,000 f? (930 m2) of floor area, with a minimum of two tests the capacity of the scale is reached. The weight in
per floor. No bond-strength testing shall be conducted until the pounds (or kilograms) at the time of cohesive/adhesive
SFRM is completely cured. Where necessary, ventilation shall be failure shall be noted.
provided so that curing is expedited. The SFRM manufacturer
shall be contacted for specific recommendations. 5.5.5.1 Nondestructive Testing. Where nondestructive testing is
conducted, the spring scale shall be replaced with fixed weight. A
5.5.4 Test Apparatus. The following equipment shall be used to series of incremental weights, beginning with a maximum of 2 lbs
conduct density testing: (0.9072 kg}, shall be suspended slowly and carefully from the
A. Armetal or rigid plastic bottle cap, 3-1/4 in. (83 mm) in hook, perpendicular fo the surface, until the SFRM manufacturer's
diameter and approximately 1/2 in. {12 mm) deep with published product specifications, the applicable building code
a hook attached at the center point. Reference Figure 2 requirement or the project specifications criteria for bond strength
(page 19) for an example. Caps are available from fab- (psf) have been met. SFRM applications meeting the requirement
oratory supply houses or bottle suppliers. are to be deemed as having passed and shall be so noted in the
B. A two-component adhesive system of urethane resin to test report. SFRM applications that do not meet the manufacturer's
férm a rigid foam or other acceptable adhesive. Refer- product specifications or the project specifications criteria are to
ence Appendix C for sources of two-component ure- be deemed to have failed and also shall be noted in the report.
thane resin systems. Consult the applicable building code and construction specifica-
C. Weighing scale, spring type (fish hook), capacity of 25 tions for acceptability of nondestructive testing procedures.
to 66 Ibs (12 to 30 kg), with an accuracy within 1/4 Ib
(0.1 kg). Note: The ASTM Standard E736 requirement that an increasing
D. A 12-in. (300-mm) square template. force (either uniform or step-wise) be exerted at the rate of
approximately 11 Ibs (5 kg) per minute until failure occurs or the
5.5.5 Methodology. Specimens of SFRM shall be secured and capacity of the scale is reached is not fo be construed to mean
tested in the following manner: that applied SFRM must sustain a total of 11 Ibs (5 kg) of weight
A. A12-in. {300-mm) square area shall be selected at the for a period of one {1} minute to meet minimum bond strength
predetermined location. Where an area of this size is requirements. The ASTM requirement specifies that an increasing

18 19
force {i.e., foot-pounds, applied incrementally) be exerted at an E. Approximate area of material involved in the failure, if it
11 Ibs (5 kg) per-minute rate of application (from the moment extends beyond the perimeter of the test cap.
the test begins until the end of one minute) perpendicular to the F. Thickness of SFRM, inches (or millimeters).
surface until failure occurs or the capacity of the scale is G. Density of the SFRM, pound/cubic foot (or
reached. To apply the force, a spring scale may be attached to kilogram/cubic meter).
the hook on the test cap and slowly drawn at a uniform rate per-
pendicular to the surface; or the spring scale can be replaced 5.5.8 Bond-Strength Correction. Where bond-strength measure-
with an incremental series of fixed weights. ments have failed to meet the specified criteria, the owner's repre-
sentative (architect or engineer} shall determine remedial proce-
To calculate the approximate weight that must be sustained prior dures. The correction method shall not adversely affect building-
to failure of the applied SFRM fo meet bond strength require- code compliance or compliance with the project specification.
ments, insert the manufacturer's product specification or the pro-
ject specification criteria for the cohesive/achesive force (psf) 5.5.8.1 Bonding Agents. Certain UL and ULC fire-resistance rat-
and an accurate measurement of the area of the test cap (f) into ing desig- criteria allow the use of classified bonding agents or
the formula in Section 5.5.6. The weight sustained by specific mechanical attachments on primed, painted or encapsulated sur-
SFRM in successfully meeting bond-strength requirements varies, faces to obtain the minimum required bond strength where the
Contact the SFRM manufacturer for inforrtation. bond strengths are found to be below minimum acceptable val-
ues. The use of classified bonding agents shall be limited to
Project specifications or applicable building-code provisions columns, beams, joists and galvanized, UL- or ULC-classified
require that applied SFRM attain a minimum specified bond primed/painted floor and roof deck units. See Section 3.2.1. The
strength. For example, building construction specifications for US appropriate UL or ULC publication shall be consulted for the spe-
General Services Administration projects require that applied cific design criteria. The SFRM manufacturer shall be consulted
SFRM have a minimum bond strength of 150 Ibs per fF (150 for specific recommendations.
Ibs/fP), and the UBC requires that SFRM applied to steel have a
minimum bond strength of 20 times the weight of the in-place
SFRM {but not less than 150 psf} when tested in accordance with 6. Condition of Finished Application
ASTM E736. Consult the construction specifications and applica-
ble building code for specific requirements. 6.1 Visual Inspection. SFRM applied to structural members or
assemblies shall not, upon complete drying or curing, exhibit
5.5.6 Calculation. The cohesive/adhesive force shall be calculat- deep or wide cracks, voids, spalls, delamination or any exposure
ed as follows: of the substrate. The surface appearance of spray-applied SFRM
CA =F/A can be described as a rough texture when compared to the
Where: CA= cohesive/adhesive force, psf (kPa), smoother surface of trowel-applied SFRM. Minor surface irregu-
F= recorded force, Ibs-force (Ibf or Newtons [N]}, and larities of spray-applied SFRM are inherent with spray applica-
A= area of the metal or plastic cap, ff (m?). tion and shall be deemed acceptable.

Note: The cap specified in Section 5.5.3.A has an area of 6.2 Correction of Deficiencies. Defects noted during the visual
0.0576 fP (5.36 x 107 nm’). inspection shall be repaired with the same SFRM as applied to the
fire-rated structural member or assembly so that the fire rating is
5.5.7 Test Report: Bond Strength. The completed test report shall maintained and specified performance requirements are met.
contain all applicable information as required in Section 5.4.7
with the addition of the following:
A. Force, pounds-force (or newtons). 7. Patching
B. Calculated cohesive/adhesive force, pounds-force per
square foot (kilo-pascals). 7.1 Patching. When SFRM has been removed for any purpose, it
C. Cohesive/adhesive force as detailed in manufacturer's shall be replaced.
published product specification.
D. Description of the type of failure. 7.2 Patching Material. All areas to be repaired shall be
(1) Cohesive failure, if separation occurred within resprayed, or patched by troweling, with the same SFRM as used
the SFRM. for the original application or with the manufacturer's recom-
(2) Adhesive failure, if separation occurred at the mended patching material.
interface of the substrate and the SFRM.

20 21
 Appendices CONCRETE
=p fa

Appendix A—Permanent Test Report

Records and Illustrations

A.1 Thickness of SFRM on Floor (Deck) Section

CONCRETE —» fore vat Sa ‘
| «+ METAL DECK
Lay out a 12 in. x 12 in. (300 mm x 300 mm) square and
take 4 random symmetrical measurements on each of the
following: (1) valley, (2) crest and (3) sides, for a total of
12 measurements.

: LOCATION CREST SIDES VALLEY FLAT PLATE

TOTAL
| AVERAGE

Date Average Required

Inspector Average Recorded

22 23
 A.2 Thickness of SFRM on Beam

12" 4 ‘
Take 9 measurements at each end of 12-in. length

*
LOCATION ] 2 3 4 5 é* 7 8 9 Total’ | AVERAGE

I 1 | \
! ' : \ \ Beam:

nen wecateten [Tora |

where reduced thicknes:
secon ai
Average Recorded
plied under W/D formula.
WERAGE — :
7 v Flange Tip (W/D):
AVERAGE* Average Required

Date Inspector Average Recorded

24 25
 A.3 Thickness of SFRM on Joists and Trusses

te iz
Take 7 measurements from around joist
or truss at each end of 12-in. length.

LOCATION ] 2 6 7 Tota | AVERAGE

I
i
i
{
{i

Date Thickness Required

Inspector Thickness Recorded

26 27
 A.4.1 Thickness of SFRM on W-Shape Columns

Take 12 measurements at each end of 12-in. length.

Locanon} J 2};3),4*)] 5 | 6] 7 10* 1] 12* TOTAL AVERA

| | !
I i '

fr]
I t

|_| AVERAGE*
[ AVERAGE | [ J+] J+ Lo] =
Note: *Average the Flange Tip measurements separately where reduced thicknesses
Column:
are applied under W/D formula, Average Required
Average Recorded
Date Flange Tip (W/D):
Average Required
Inspector Average Recorded

28 29
i

PWR emma Wee M eS) k eens

ts
Take a minimum of 4 measuremen at each end of 12-in.
length.

x x
x f

| x} x x

|
i

: |
LOCATION | 3 A Tota | AVERAGE i LOCATION ] 2 3 4 TOTAL | AVERAGE

Date ! Average Required

inspector | Average Recorded

30 | 31
 eTTCUTR
Appendix B—Alternate Method for Bond B.1.3 Test Procedure.
Strength (Cohesion/Adhesion) of SFRM
B.1.3.1. Using the epoxy, the wooden disk shall be adhered into
Exceeding 1,146 PSF

rere
the hole. The epoxy shall be allowed to fully set and cure.
Note: This test method is recommended for products that have
bond strengths exceeding 1,146 psf. B.1.3.2. After the epoxy has fully cured, the test sample shall be
suspended face down in the top jaw of the tensile machine.
B.] Laboratory Method.
B.1.3.3. The eye screw that is attached to the wooden disk shall
B.1.1. Required Apparatus. be attached fo the lower jaw of the tensile machine so that the
lower jaw of the machine is perpendicular fo the test sample.
B.1.1.1. Wooden disk 1 3/8 in. (34 mm) diameter, 1 in.
(25 mm} thick with 1/4 in. (6 mm) eye bolt screwed perpendicu- Note: Failure to properly align the test material in the machine
larly into center of disk. may result in shearing of the test sample and produce results that
are not indicative of the material's true bond strength.
B.1.1.2. Two-component epoxy adhesive with a minimum 4,000
psi strength. {also known as two-ton epoxy). B.1.3.4, Tensile machine shall be set to a crosshead speed of
0.05 in./min. Machine shall be started and continued until sam-
B.1.1.3. Standard hydraulic tensile machine. ple failure.

B.1.1.4. Load cell with 1,000 Ib. (453 kg) capacity. B.1.3.5. Peak load at material failure shall be recorded.

B.1.1.5. Drill press. B.1.4 Calculations.

B.1.1.6. Fostner bit, 36 mm.

B.1.4.1. Cohesion/adhesion {bond) strength shall be calculated as
CA=F/A
B.1.2. Somple Preparation. Where:
CA = cohesive/adhesive strength (lb/ft),
B.1.2.1. Material to be tested shall be applied to a 11.5 in. (292 F = recorded force (Ib),
mm) by 12.5 in. (318 mm) by 1/4 in. (6 mm) steel plate. A = area of wood disk (f?).

B.1.5 Report.
8.1.2.2. Material shall be applied according to the manufactur-
er’s directions to the steel substrate in a thickness not Jess than
B.1.5.1. Material manufacturer name, product name, material
3/4 in. (19 mm).
density, material thickness tested and cohesion/adhesion (bond}
B.1.2.3. Material shall be screeded to a smooth and level surface test strength results shall be reported.
and allowed jp set and cure as recommended by the manufactur-
B.2 Field Procedure.
er. To avoid inconsistent results, all material shall be dry. Material
containing cement shall be cured for a minimum of 28 days.
Note: WARNING! This standard may involve hazardous materi-
als, operations and equipment. This standard does not purport
B.1.2.4. Fully cured and dried sample shall be placed in a drill
press in a perfectly level position. to address all of the safety problems associated with its use. It
is the responsibility of the user of this standard to establish
B.1.2.5. Following attachment of the Fostner bit to the drill press, appropriate safety and health practices and determine the
a hole shall be drilled in the center of the sample. The hole shall applicability of regulatory limitations prior to use.
be deep enough to establish a smooth even surface for the
B.2.1 Required Apparatus.
adhering of the wooden disk, but in no instance shall the hole be
less than 1/4 in. (6 mm) deep.
B.2.1.1. Wooden disk 1 3/8 in. (34 mm] diameter, 1 in. (25
B.1.2.6. The sample shall be inspected for loose dust, dirt or any mm) thick with 1/4 in. (6 mm) eye bolt screwed perpendicularly
loose material that will impair the adhesive quolity of the epoxy.
into center of disk.

32- 4 33
B.2.1.2. Two-component epoxy adhesive with a minimum 4,000 B.2.4 Calculations.
psi strength (also known as two-ton epoxy).
B.2.4.1. Cohesion/adhesion (bond) strength shall be calculated as:
B.2.1.3. Portable load cell with 1,000 Ib (453 kg) capacity. CA=F/A \
Where:
B.2.1.4. Drill. CA = cohesive/adhesive strength (lb. /f?),
F = recorded force (Ib),
B.2.1.5. Fostner bit, 36 mm. A = area of wood disk (f?).

B.2.1.6. Level. B.2.5 Report.

B.2.2 Sample Preparation. B.2.5.1. Material manufacturer name, product name, material
density, material thickness tested and cohesion/adhesion (bond)
B.2.2.1. Material shall be applied according to the manufactur- test strength results shall be reported.
er’s directions to the substrate in a thickness not less than 3/4 in.
(19 mm). This procedure shall not be used for testing of material
thicknesses less than 3/4 in. (19 mm).
Appendix C-Resource Materials and
Test Apparatus
B.2.2.2. Material shall be allowed to set and cure as recom-
mended by the manufacturer. To avoid inconsistent results, all Resource Materials,
moterial shall be dry. Material containing cement shall be cured
for a minimum of 28 days. The following standards, building-code provisions and reference
documents were utilized in the development of this standard
B.2.2.3. Following attachment of the Fostner bit to the drill, a practice:
hole shall be drilled in the center of the sample. The hole shall be
deep enough to establish a smooth, even surface for the adher- Standard Test Methods for Thickness and Density of Sprayed
ing of the wooden disk, but in no instance shall the hole be less Fire-Resistive Material (SFRM) Applied to Structural Members, E
than 1/4 in. (6 mm) deep. 605-93, American Society for Testing and Materials, West Con-
shohocken, PA.
B.2.2.4. The sample shall be inspected for loose dust, dirt or any
loose material that will impair the adhesive quality of the epoxy. Standard Test Method for Cohesion/Adhesion of Sprayed Fire-
Resistive Materials (SFRM) Applied to Structural Members, E
B.2.3 Test Procedure. 736-92, American Society for Testing and Materials, West Con-
shohocken, PA.
B.2.3.1. Using the epoxy, the wooden disk shall be adhered into
the hole. The epoxy shall be allowed to fully set and cure. Standard Practice for Application of Sprayed Fire-Resistive Mate-
rials (SFRMs), E 1513-93, American Society for Testing and
B.2.3.2. The eye screw that is attached to the wooden disk shall Materials, West Conshohocken, PA.
Be attached to the load cell using an “S” hook. The test shall be
positioned so that the “pull” is perpendicular to the sample. Fire Resistance Directory, 1996 issue, Underwriters Laboratories
Inc., Northbrook, IL.
Note: Failure fo properly align the fest material may result in
shearing of the test sample and produce results that are not List of Equipment and Materials, Volume 11, Building Construc-
indicative of the material’s frue bond strength. tion, 1996 edition, Underwriters Laboratories of Canada, Scar-
borough, Ontario.
B.2.3.3. The load cell shall be pulled using a steady, perpendicu-
lar force at a maximum rate of 50 Ibs/min. Thickness, Density, and Cohesion/Adhesion Determination for
Spray-Applied Fireproofing, Uniform Building Code Standard
B:2.3.4, Peak load at material failure shall be recorded. No. 7-6, 1995 edition, International Conference of Building Offi-
cials, Whittier, CA.

34 35
Inspection of Spray-Applied Fire Resistant Materials, Section Ohio Sealants, Inc.
1709 Standard Building Code, 1988 edition, Southern Building 7405 Production Drive
Code Congress International, Inc., Birmingham, AL. Mentor, OH 44060
(216} 951-5678
MASTERSPEC, Section 07250, Sprayed-On Fireproofing, 1992,
American Institute of Architects, Washington, D.C. Red Devil, Inc.
2400 Vauxhall Road
Design Selection Utilizing Sprayed Fire Protection, 1993 edition, Union, NJ 07063
The Association of the Wall and Ceiling Industries—international, (908) 688-6900
Falls Church, VA.
Approved thickness measuring gauges and devices are available
Test Apparatus. from various sources of supply, including

Two-component urethane resin adhesives for use in adhering test The Association of the Wall and Ceiling Industries—
caps to SFRM during bond-strength testing are available from International
various sources of supply, including those listed below. Contact 307 E. Annandale Road, Suite 200
the adhesive manufacturer to determine product suitability. Falls Church, VA 22042
Phone {703} 534-8300
Brim Products Co., Inc. Fax (703) 534-8307
6531 S.W. 20th Court
Plantation, FL 33317 Bottle screw caps are available from various sources of supply,
(954) 584-1150 including those listed below. Contact supplier to determine avail-
ability of cap that complies with requirements outlined herein.
C &R Products Co.
Div. of Clothier & Rose.Inc. Andler Bottle Co.
“1000 E. Del Amo Blvd. 376 Third St.
Carson, CA 90746 Everett, MA 02149
(310) 537-2800 (617) 387-5700

Fomo Products, Inc. Thomas Scientific Co.

2775 Barber Road ' 99 High Hill Road
P.O. Box 1078 : Swedesboro, NJ 08085
Norton, OH 44203 (609) 467-2000
(330) 753-4585

Insta-Foam Products, Inc. Appendix D-Conversion Factors

1500 Cedarwood Drive
Joliet, IL 60435 Conversion Factors. The following conversion factors shall be
(815) 741-6800 used when calculating density in accordance with the formulae
t referred to in this document:
Clayton Corp./Convenience Products, Inc. 1 pound (Ib) = 0.4536 kilogram (kg)
866 Horan Drive ‘ 1 kilogram (kg) = 2.204 Ib
Fenton, MO 63026 1 ounce (oz) = 28.359 grams (g)
(31.4) 349-5333 1 gram (g) = 0.035 ounce {oz)
1 inch (in) = 0.0254 meter (m)
Mine Safety Appliance Co. 1 meter (m) = 39.37 inches (in.)
Walden Road 1 inch (in.) = 25.4 millimeters (mm)
Cranberry Township, PA 16066 i 1 millimeter (mm) = 0.04 inch (in)
(412) 967-3000 : 1 cubic meter (m?) = 35.3 cubic feet (f°)
1 cubic foot (ff?) = 0.028 cubic meters (m*)
1 cubic inch (in?) = 16.387 cubic centimeters (cm)
1 cubic meter (m*) = 61023 cubic inches (in’)

36 37