Test report. Fire resistance test of a loadbearing wall according to NS- EN :2012. SPU AL 100 and SPU FR 70 insulated light-weight wall panel

Transcription

1 -B - Restricted Test report Fire resistance test of a loadbearing wall according to NS- EN :01 SPU AL 100 and SPU FR 70 insulated light-weight wall panel Author Espen Daaland Wormdahl SINTEF NBL as Fire Resistance

2 SINTEF NBL as SINTEF NBL as Address: Postboks 4767 Sluppen NO-7465 Trondheim NORWAY Telephone: Enterprise /VAT No: NO MVA Test report Fire resistance test of a loadbearing wall according to NS-EN :01 SPU AL 100 and SPU FR 70 insulated light-weight wall panel DATE NORWEGIAN ACCREDITATION TEST 014 KEYWORDS: Fire resistance NS-EN :01 Loadbearing wall AUTHOR Espen Daaland Wormdahl CLIENT SPU Oy Sillanpäänkatu Kankaanpää, FINLAND TEST OBJECT Loadbearing wall CLIENT S REF. Niklas Alexandersson NUMBER OF PAGES AND APPENDICES 40 incl. 4 appendices TEST OBJECT RECEIVED TEST PROGRAM NS-EN :01 TEST LOCATION SINTEF NBL as DATE OF TEST ABSTRACT The test was performed on a wall made of timber frame work insulated with PIR insulation and Rockwool. The wall was exposed to fire towards the wood panelling side and with Gypsum boards on unexposed side of the wall. The dimension of the wall was 3000 x 995 mm (width x height). The thickness was 86 mm. Seen from the exposed side, the wall consisted of 1.5 mm Gyproc GN13 gypsum board, 50 mm Rockwool Flexi A-plate insulation (measured density 3 kg/m 3 ), 48 x 148 mm timber studs, 100 mm SPU AL 100 PIR insulation, 70 mm SPU FR 70 PIR insulation, 36 x 48 mm furring strips and 19 x 148 mm timber panel. The wall was loaded with 44 kn/m applied as an evenly distributed load centrically on top of the wall, totally 13 kn The test was performed according to NS-EN :01 with reference to NS-EN :1999 for documentation of fire resistance. See the test report for a detailed description of the wall. The test results relate only to the items tested. The report is the client s property and cannot be given to a third party without the client s written consent. The report shall not be reproduced except in full without the written approval of SINTEF 1 of 8

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4 Document history DATE DESCRIPTION OF Original test report Updated text and drawings. -B 3 of 31

5 Table of contents 1 TEST RESULTS Visual observations during the test Visual observations after the test Temperature in furnace hall: Instrumentation of the test specimen Graphic presentation of test results Photos before, during and after test PREPARATION OF TEST SPECIMEN Material properties: Mechanical applied load Drawings... 0 A Appendix I - TEST CONDITIONS... 1 B Appendix II - STATEMENT ACCORDING TO NS-EN : C Appendix III - FIELD OF DIRECT APPLICATION... 1 D Appendix IV - CRITERIA FOR CLASSIFICATION ACCORDING TO NS-EN B 4 of 31

6 1 TEST RESULTS The test results are documented as: - Visual observations during and after the test. - Measurements on the test specimen. - Video recording of the test and photos taken before, during and after the test. - Pressure and temperature inside the furnace (Appendix I). 1.1 Visual observations during the test The following observations were made on unexposed side of the specimen, unless otherwise specified. Time [min:sec] Observations 00:00 Start. 03:0 1:00 The timber panel on exposed side is on fire. Thin smoke appears between the wall and the top of the frame. No other smoke or damage is visible on the unexposed side. 17:00 The timber panel is black, and little flames are visible. 1:00 The timber panel has probably fallen off, due to more visible flames on the exposed side. 9:30 Yellow smoke develops between the upper left side of the wall and test frame on unexposed side. 34:00 Some yellow smoke development between top of the wall and test frame. 43:00 Still some smoke development between top of the wall and test frame. 53:30 The smoke development in the top decreases. 60:00 No visible damage on unexposed side. No need for cotton pad or gap gauge test. 70:00 Still no visible damage on unexposed side. Termination of the test. After termination of the test, the restraint frame with the test specimen was removed from the furnace for cooling and inspection. 1. Visual observations after the test Side Exposed side Unexposed side Observations after test Some of the SPU-insulation has fallen out of the wall and is lying on the furnace floor. The insulation boards are charred, porous and stiff. There are some remnants of the Aluminum foil on both sides of the insulation boards. The insulation boards are stiff on the outer sides and more porous in the center of each board. Most of the FR 70 layer has fallen off. The timber studs are still in place, but charred by fire. On the unexposed side of the wall, the gypsum boards are undamaged. -B 5 of 31

7 1.3 Temperature in furnace hall: Test start Stop Average 18 C 19 C 18 C 1.4 Instrumentation of the test specimen The test specimen was instrumented in accordance with requirements in the test standard NS-EN :01. Thermocouples on unexposed side for registration of temperature (TC0 TC3) Deflection measurements for horizontal deformation were placed in the center of the wall (Defl. 1) and in ½ height of the wall, 50 mm in from free edge (Defl. ). Deflection measurements for vertical deformation were placed on the load system, measuring the compression/deformation in the wall caused by the applied load. In addition to this, thermocouples were installed inside the wall for information purpose. These measurements inside the wall should be used in the analysis of the behavior of the PIR-insulation (TC1 TC19). Positions for the temperature measurements and deflection measurements are described in the enclosed sketch in figure 1 (not in scale) and table 1. Figure 1: Principal sketch of positions for thermocouple no. 0 to 3 mounted on the gypsum boards on unexposed side of the wall. The deflection measurement is also shown in no. 33 and 34. -B 6 of 31

8 Figure : Principal sketch of positions for thermocouple no. 1 to 19 mounted inside the wall. Table 1: Listed position of temperature measurements inside the wall (TC1-TC19 for information purposes), TC0-TC3 on the unexposed face, and deflection measurements (Defl. 1-4). TC no. Position (seen from unexposed side) 1 On stud between FR 70 and AL 100, /3 height. 13 On stud between AL 100 and RW 50, /3 height. 14 On stud between gypsum board and RW 50, /3 height. 15 Between gypsum board and RW 50, /3 height centre of wall. 16 Between AL 100 and RW 50, /3 height, ½ width. 17 Between FR 70 and AL 100, /3 height, ½ width. 18 Between FR 70 and AL 100, mid-height, ½ width. 19 Between AL 100 and RW 50, mid-height center of wall. 0 In centre of lower ¼ section, left hand side on gypsum board. 1 In centre of lower ¼ section, right hand side on gypsum board. In center of wall on gypsum board. 3 In centre of upper ¼ section, left hand side on gypsum board. 4 In centre of upper ¼ section, right hand side on gypsum board. 5 NS-EN :01: Section : Thermocouple a) 6 NS-EN :01: Section : Thermocouple b) 7 NS-EN :01: Section : Thermocouple d) 8 NS-EN :01: Section : Thermocouple c) 9 NS-EN :01: Section : Thermocouple e) 30 NS-EN :01: Section : Thermocouple c) 31 NS-EN :01: Section : Thermocouple f) 3 NS-EN :01: Section : Thermocouple f) Defl 1 (33) Horizontal deflection in the center of the wall. Defl (34) Horizontal deflection in ½ height of the wall, 50 mm in from right side edge. Defl 3 (35) Vertical deflection (mounted to load system), left side Defl 4 (36) Vertical deflection (mounted to load system), right side -B 7 of 31

9 C C 1.5 Graphic presentation of test results Temperatures Minutes Chan 1 Chan 13 Chan 14 Chan 15 Chan 16 Chan 17 Chan 18 Chan 19 Figure 3: Temperature measured inside wall. These measurements are for information purpose. Temperatures Chan 0 Chan 1 Chan Chan 3 Chan Minutes Figure 4: Temperature measured on the gypsum boards on unexposed side of the wall (TC0- TC4). -B 8 of 31

10 C C Temperatures Minutes Chan 5 Chan 6 Chan 7 Chan 8 Chan 9 Chan 30 Chan 31 Chan 3 Figure 5: Temperature measured on the gypsum boards on unexposed side of the wall (TC5- TC3). Maximum and average temperature rise Average temp. rise Maximum temp. rise Avg. Crit. Max. Crit Minutes Figure 6: Average temperature rise calculated for TC0-TC4 and maximum temperature rise calculated for TC0-TC3. The criteria limits of ΔT 140 C and ΔT 180 C are also shown. -B 9 of 31

11 mm mm Deflection measured on wall 1,5 1 0,5 0-0,5-1 Chan 33 Chan 34-1,5 - -, Minutes Figure 7: Deflection measured in centre of the wall (33) and 50 mm in from the edge in ½ height of the wall (34). Negative values indicate deflection away from the furnace. Vertical contraction 35,0 30,0 5,0 0,0 15,0 10,0 Contraction 35 Contraction 36 Contraction limit 5,0 0, Minutes Figure 8: Vertical contraction. The limiting vertical contraction C=h/100 is shown. -B 10 of 31

12 mm/min Vertical contraction rate Rate of contraction 35 Rate of contraction 36 Maximum rate of contraction Minutes Figure 9: Vertical contraction. The limiting rate of vertical contraction dc/dt=(3h)/1000 is shown. 1.6 Photos before, during and after test Figure 10: Inside the wall during mounting. The rear side of FR 70 is covering the wall behind the studs. -B 11 of 31

13 Figure 11: Unexposed side during mounting. Figure 1: The timber panel on exposed side of the test specimen before test start. -B 1 of 31

14 Figure 13: The unexposed side of the test specimen before the test start. Figure 14: The unexposed side of the test specimen 30 minutes into the test. -B 13 of 31

15 Figure 15: The unexposed side of the test specimen 45 minutes into test. Figure 16: The unexposed side of the test specimen 60 minutes into test. -B 14 of 31

16 Figure 17: The unexposed side of the test specimen 70 minutes into test. The test was terminated at that point. Figure 18: The exposed side right after test. -B 15 of 31

17 Figure 19: The exposed side after cooling down. Figure 0: A section cut of the AL 100 and RW 50 (Rockwool) layers inside the wall. -B 16 of 31

18 PREPARATION OF TEST SPECIMEN Constructional details: The test was performed on a wall made of timber framework insulated with PIR insulation and rock wool. The wall was exposed to fire towards the wood panelling side and with Gypsum boards on unexposed side of the wall. The dimension of the wall was 3000 x 995 mm (wxh) and the thickness was approximately 86 mm. Seen from the exposed side, the wall consisted of 19 x 148 mm timber panel, 36 x 48 mm vertical furring strips (called studding battens on drawings), 70 mm SPU FR 70 PIR insulation, 100 mm SPU AL 100 PIR insulation, 48 x 148 mm timber studs, 50 mm Rockwool Flexi A, and 1.5 mm Gyproc GN13 gypsum board. The gypsum board had the dimension 100 x 400 mm (wxh) and was fastened to the timber frame work with 3,8 x 3 mm and 3,9 x 30 mm screws. The centre distance between the screws on the perimeter of the gypsum board was 00 mm and over the stud in the centre of the board the distance was 300 mm. In the gypsum board joints, a 50 mm wide paper strip and layers of Nordsjö medium filler was used. The timber framework was made of wood studs with dimension 48 x 148 mm (wxh) of quality C4 fixed together with 5x90 mm screws and with a centre distance of 600 mm between the studs. One horizontal wood stud was mounted at height 400 mm to support the edge of the gypsum board. 50 mm Rockwool Flexi A insulation were laid in the timber framework between the timber studs towards the gypsum boards. SPU AL 100 PIR insulation boards were laid between the wood studs in the timber frame work. The SPU AL 100 boards were 50 mm wide and the height varied depending on the framework. One horizontal joint between the SPU AL 100 boards was filled with Tytan PU foam. Between SPU AL 100 board and the wood studs, the 15 mm gaps on all 4 sides of each insulation board were filled with Tytan PU-foam for the whole depth. The SPU AL 100 insulation boards were 100 mm thick and had aluminium foil/laminate on both sides of the boards. The nominal thickness of the multilayer aluminium laminate (14 g/m ) was 115±15 µm and the thickness was measured to approximately 0.1 mm. On the exposed side of the timber framework, 70 mm thick SPU FR 70 insulation boards were fastened with Ø3 mm washers and screws 5 x 100 mm, six in each board. SPU FR 70 insulation board had a black mineral coated fibre glass laminate with graphite on one side (nominal thickness was 1,1 mm and the thickness was measured to approximately 0,8-1,0 mm) and a white mineral coated fibreglass laminate on the other side (nominal thickness was 0,6 mm and the thickness was measured to approximately 0,5 mm). The black side of the SPU FR boards were mounted towards the air gap behind the furring strips and wood panelling. Tytan PU-foam was used to seal the horizontal gap between the concrete frame and SPU FR 70 boards on the bottom edge. Each insulation board with Rockwool Flexi A were glued to SPU AL 100 with two vertical stripes of Tytan foam and each board with SPU AL 100 were glued to SPU FR 70 with two vertical stripes of Tytan foam. 6 x 140 mm screws were used to fix furring strips 36x48 mm on the wood studs (48 x 148 mm). Vertical battens were screwed in top and bottom, and centre distance between the screws was approximately 600 mm. The dimensions of the SPU FR 70 boards and positions of the joints between the boards are shown on drawings delivered by the client. The horizontal joint between SPU FR 70 board at mid width were moved 150 mm below the horizontal joint between the SPU AL 100 boards (standard overlapping -B 17 of 31

19 distance between joints at the same position in different insulation layers). The joints between SPU FR boards were filled with Tytan PU foam. Wood panel with dimension 19x148 mm were fastened to each vertical furring strip with nails with dimension.8 x 75 mm. At the bottom of the wood panelling there was app. 15 mm wide ventilation gap on the unexposed side. Information on the laminates on the FR 70 boards: Black side: Black mineral coated fiberglass laminate, thickness 1,1mm ± 15% White side: Light mineral coated fiberglass laminate, thickness 0,6mm ± 15% On pages 7 to 31 information sheets for PIR-insulation and Tytan foam are enclosed. Some more information regarding the mineral coating/laminates are in the archived file for this test at SINTEF NBL. Detailed information of the design of the wall is given on the enclosed drawings delivered by the client. OVERALL DIMENSIONS OF THE WALL: Authentication: 3000 x 995 mm (w x h) Thickness 86 mm THICKNESS OF SPU AL 100 INSULATION: THICKNESS OF SPU FR 70 INSULATION: THICKNESS OF Rockwool Flexi A: 100 mm 70 mm 50 mm SINTEF NBL controlled the drawings supplied by the client, and found these to be in accordance with the test specimen. Manufacturer (-s) and place of production: 1. SPECIMEN: PLACE OF PRODUCTION: Loadbearing wall construction SINTEF NBL as. COMPONENTS/FITTINGS: MANUFACTURER / SUPPLIER SPU AL 100 and SPU FR 70 Gypsum board, Gyproc GN13 Tytan PU Gun foam Rockwool Flexi A SPU Oy, Finland Gyproc AS (Saint Gobain), Norway Selena FM S.A., Poland Rockwool A/S, Denmark Mounting of the wall: Technicians from SINTEF NBL as built a 3000 mm x 995 mm (wxh) wall in the concrete loading frame. The wall was mounted in line with the exposed side of the loadbearing restraint concrete test frame. In bottom of the frame, the sill of the wall was fastened with stripes of sealing compound on top of a bitumen underlay towards the concrete frame. Between the side edges of the loadbearing restraint concrete frame and test specimen one layer of 30 mm thick hard Rockwool was placed to close the gap and to create a free edge. The wall was exposed from gypsum board side. Conditioning: The wall was built up in the concrete loading frame in the laboratory test hall in the period from arrival of materials and until the date of testing Measurements of the moisture content in the wood studs, furring strips and wood panel were found to be between 11. % and 1.7 %. The Tytan PU-foam was mounted in the wall two days before the test. Selection of the test specimen: SINTEF NBL was not involved in the selection of the materials for the fire test. The design of the wall was decided by the client. -B 18 of 31

20 .1 Material properties: Some material properties for the insulation used in the specimens are presented in the following table. The measurements of density for PIR insulation are performed on relatively small samples taken from material provided by the client. Table Density for PIR and Rockwool insulation. Material Nominal thickness (mm) Nominal density (kg/m 3 ) Measured density (kg/m 3 ) Measured density (kg/m 3 ) SPU FR ) ) 5.6 ) SPU AL ) ) 35.0 ) Rockwool Flexi A Measured density for only the PIR-insulation. Measured density for PIR-insulation including foil and laminates. Mechanical applied load The wall was loaded with 44 kn/m applied as an evenly distributed load centrically on top of the wall, totally 13 kn. The wall was loaded with a horizontal loading beam on the top of the wall. The load was applied 15 minutes before the fire test started and was maintained throughout the test. Loading value was given by the client. This load corresponds to a pressure level of 6.7 bar on the load-system, which was manually controlled and supervised during the course of the test. -B 19 of 31

21 .3 Drawings Drawings and product data sheet received from the client are enclosed on the following pages (not in scale). Drawing 1. -B 0 of 31

22 Drawing. -B 1 of 31

23 Drawing 3. -B of 31

24 Drawing 4. -B 3 of 31

25 Drawing 5. -B 4 of 31

26 Drawing 6. -B 5 of 31

27 Drawing 7. -B 6 of 31

28 Product data sheet of PIR Insulation. -B 7 of 31

29 -B 8 of 31

30 -B 9 of 31

31 -B 30 of 31

32 Tytan PU Gun foam: -B 31 of 31

33 A Appendix I - TEST CONDITIONS Test method The test was carried out in accordance with NS-EN :01, Fire resistance tests for loadbearing elements - Part 1: Walls. See remarks/deviations on page 3. Carrying out the test The test was carried out in the laboratory's gas-heated vertical furnace as described below. The wall was installed into a restraint frame made of steel and concrete. The fire exposed area in the test frame was 3030 x 995 mm (bxh). The restraint frame with the specimen was positioned in front of the furnace opening, and the specimen was tested vertically. The furnace was heated in accordance with the standard time/temperature-curve given in NS-EN :1999. The following persons witnessed the test Representative: Niklas Alexandersson Torstein Svennevig Organisation: SPU SPU -B A1 of A4

34 Test furnace The furnace has inner dimensions 3060 x 3060 x 100mm (w x h x d). See Figure A TEST WALL Pressure and temperature in the furnace was registered during the test and are graphically presented in this Appendix. Results and deviations are given according to NS-EN :1999. The furnace temperature was measured by 9 plate thermocouples positioned 100 mm from the exposed side of the specimen. The furnace thermocouples were of type "plate" as described in in NS-EN and the measurement of the furnace temperature was done according to 5.1 in NS-EN The positions of the thermocouples in the furnace are shown in figure A1. The pressure in the furnace was measured by means of a pressure sensor of Type 1 ("T"-shaped sensor) as described in 5. in NS-EN The pressure sensor was located 500 mm above the test furnace floor. With a pressure gradient of 8,5 Pa/m, the pressure in this level was calculated to be 16 Pa. The furnace should be controlled after this value to establish a pressure of zero, at a height of 500 mm above the notional floor level of the specimen. FRONT VIEW SIDE VIEW mm from specimen PRESSURE FLUE DUCT TC-rods FLUE DUCT FRAME Figure A.1 Location of thermocouples and pressure sensor inside the test furnace, 100 mm from the exposed side of the test specimen. -B A of A4

35 C C Presentation of pressure and temperature in furnace 100 Furnace temperatures Minutes Figure A. Furnace temperatures. Deviation limits after 10 minutes. Average furnace temperature Average furnace EN Minutes Figure A.3 Average temperature inside the furnace, and the standard time/temperature curve. -B A3 of A4

36 Pa % Furnace temperature deviation Minutes Figure A.4 Percentage deviation between average furnace temperature and standard time/temperature curve. Furnace pressure Figure A Minutes Pressure in the furnace, measured at.5 m above furnace floor, and deviation limits. Intended furnace pressure: 16 Pa. -B A4 of A4

37 B Appendix II - STATEMENT ACCORDING TO NS-EN :1999. This report details the method of construction, the test conditions and the results obtained when the specific element of construction described herein was tested following the procedure outlined in EN , and where appropriate EN Any significant deviation with respect to size, constructional details, loads, stresses, edge or end conditions other than those allowed under the field of direct application in the relevant test method is not covered by this report. Because of the nature of fire resistance testing and the consequent difficulty in quantifying the uncertainty of measurement of fire resistance, it is not possible to provide a stated degree of accuracy of the result. -B B1 of B1

38 C Appendix III - FIELD OF DIRECT APPLICATION Field of direct application of test results is described in NS-EN :1999, Annex A: -B C1 of C

39 Field of direct application of test results as described in NS-EN :01 -B C of C

40 D Appendix IV - CRITERIA FOR CLASSIFICATION ACCORDING TO NS-EN Text is shown as described in NS-EN : Loadbearing capacity: Loadbearing capacity is the ability of the element of construction to withstand fire exposure under specified mechanical actions, on one or more faces, for a period of time, without any loss of structural stability. The criteria which provide for assessment of imminent collapse will vary as a function of the type of loadbearing element. For flexurally loaded elements e.g. floors, roofs, there shall be a rate of deformation (deflection) and a limit state for the actual deformation (deflection). Integrity: The assessment of integrity shall be made on the basis of the following three aspects: a) cracks or openings in excess of given dimensions; b) ignition of a cotton pad; c) sustained flaming on the non-exposed side. Insulation: The performance level, used to define insulation, shall be the average temperature rise on the unexposed face, limited to 140 C above the initial average temperature, with the maximum temperature at any point limited to 180 C above the initial average temperature. -B D1 of D1

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