Title: Fire resistance test in accordance with BS EN : 2008 on an uninsulated, face fixed rolling shutter doorset. Report No: Prepared for:

Transcription

1 Exova Warringtonfire Holmesfield Road Warrington WA1 2DS United Kingdom T : +44 (0) F : +44 (0) E : warrington@exova.com W: Title: Fire resistance test in accordance with BS EN : 2008 on an uninsulated, face fixed rolling shutter doorset Report No: Prepared for: Bolton Gate Co. Ltd Waterloo Street, Bolton, BL1 2SP. Date: 28 th October 2011 Notified Body No: Registered Office: Exova (UK) Ltd, Lochend Industrial Estate, Newbridge, Midlothian EH28 8PL United Kingdom. Reg No.SC 70429

2 Page 2 of 36 Summary Objective Test Sponsor Summary of Tested Specimen To determine the fire resistance performance of an uninsulated rolling shutter doorset, when tested in accordance with BS EN : Bolton Gate Co. Ltd. Waterloo Street, Bolton, BL1 2SP. The rolling shutter assembly was fixed to the exposed face of a masonry wall to cover an aperture with an opening size of 2400 mm high by 2500 mm wide, such that the barrel assembly was exposed to the heating conditions of the test. Test Results: Integrity performance Insulation performance Sustained flaming Gap gauge Cotton Pad 264 minutes* 264 minutes* 23 minutes 3 minutes Date of Test 16 th September *The test duration. The test was discontinued after a period of 264 minutes. This report may only be reproduced in full. Extracts or abridgements of reports shall not be published without permission of Exova Warringtonfire.

3 Page 3 of 36 Signatories Responsible Officer N. Howard* Testing Officer Approved D. Hankinson* Principal Certification Engineer Head of Department S. Hankey* Operations Manager * For and on behalf of Exova Warringtonfire. Report Issued Date : 28 th October 2011

4 Page 4 of 36 CONTENTS PAGE NO. SUMMARY...2 SIGNATORIES...3 TEST PROCEDURE...5 TEST SPECIMEN...6 SCHEDULE OF COMPONENTS...14 SPECIMEN SUPPORTING CONSTRUCTION...16 INSTRUMENTATION...17 TEST OBSERVATIONS...18 TEST PHOTOGRAPHS...20 TEMPERATURE AND DEFLECTION DATA...24 PERFORMANCE CRITERIA AND TEST RESULTS...33 ONGOING IMPLICATIONS...33 CONCLUSIONS...34 FIELD OF DIRECT APPLICATION...35

5 Page 5 of 36 Test Procedure Introduction The doorset is required to provide a fire separating function and was therefore tested in accordance with BS EN : 2008 Fire resistance tests for doors and shutter assemblies - Part 1: Fire doors and shutters. This test report should be read in conjunction with that Standard and with BS EN : 1999, Fire resistance tests - Part 1: General requirements and BS EN : 1999, Fire resistance tests - Part 2: Alternative and additional procedures. The specimen was judged on its ability to comply with the performance criteria for integrity as required by BS EN : Fire Test Study Group/EGOLF Instruction to test Certain aspects of some fire test specifications are open to different interpretations. The Fire Test Study Group and EGOLF have identified a number of such areas and have agreed Resolutions which define common agreement of interpretations between fire test laboratories which are members of the Groups. Where such Resolutions are applicable to this test they have been followed. The test was conducted on the 16 th September 2011 at the request of Bolton Gate Co. Ltd, the sponsor of the test. Mr. D. Jones and Mr. L. Burgess representatives of the test sponsor witnessed the test. Test Specimen Construction Installation Sampling A comprehensive description of the test construction is given in the Schedule of Components. The description is based on a detailed survey of the specimen and information supplied by the sponsor of the test. The doorset was mounted over an aperture provided within a brickwork supporting construction such that the barrel was on the side facing towards the heating conditions of the test. Representatives of the test sponsor conducted the installation work on 15 th September Exova Warringtonfire was not involved in any selection or sampling procedures of the specimen or any of the components.

6 Page 6 of 36 Test Specimen Figure 1- General Elevation of Test Specimen from Exposed Face casing overall length mm maximum slot centres A mm maximum slot centres specimen restraint frame GENERAL ELEVATION OF EXPOSED FACE structural opening 100 see detail 'B' FIRE HORIZONTAL SECTION see detail 'C' Do not scale. All dimensions are in mm

7 Page 7 of 36 Figure 2 Thermocouple Positions Do not scale. All dimensions are in mm

8 Page 8 of 36 Figure 3 Typical Details of Curtain and Curtain Guide M6 expansion bolts SECTION 'A' typ. guide details 70 M6 setscrews FIRE FIRE Detail - item 10 Detail - item 9 10 Do not scale. All dimensions are in mm

9 Page 9 of 36 Figure 4 Horizontal Section at Motor End Plate M8 expansion bolts M8 setscrews M8 studs FIRE Do not scale. All dimensions are in mm

10 Page 10 of 36 Figure 5 Horizontal Section at Bearing End Plate M12 setscrews FIRE 11 Do not scale. All dimensions are in mm

11 Page 11 of 36 Figure 6 Vertical Section Through Specimen guide angle fixings to structure 2400 structural opening height FIRE guide channel 10 Do not scale. All dimensions are in mm

12 Page 12 of 36 Figure 7 Vertical Section at Bearing Endplate specimen restraint frame casing fixings to structure 347 endplate fixings to structure brickwork wall concrete lintel FIRE 48 casing fixings to endplate 10 bottom rail fully open position Do not scale. All dimensions are in mm

13 Page 13 of 36 Figure 8 Vertical Section at Motor Endplate brickwork wall 460 motor plate 6 7 ratchet drive chain concrete lintel FIRE Do not scale. All dimensions are in mm

14 Page 14 of 36 Schedule of Components (Refer to Figures 1 to 8) (All values are nominal unless stated otherwise) (All other details are as stated by the sponsor) Item Description 1. End Plate Material : Pre galvanised mild steel Thickness : 5 mm Overall size : 345 mm x 400 mm Fixing method : Fixed to masonry surround with 3 no. M8 expansion bolts. 2. Guide Angle Material : Pre galvanised mild steel Thickness : 3 mm Overall section size : 50 mm x 70 mm x 30 mm return Overall length : 2475 mm Fixing method : Fixed to masonry surround with M6 expansion bolts c/w steel and fusible washers at 450 mm maximum centres. 3. Guide Channel Material : Pre galvanised mild steel Thickness : 3 mm Overall section size : 52 mm deep x 30 mm wide Overall length : 2500 mm Fixing method : Fixed to guide angle (item 2) with M6 x 16 mm long countersunk head setscrews and hex nuts at 450 mm maximum centres. 4. Barrel Material : Mild steel tube Thickness : 1.6 mm Overall size : mm diameter x 2680 mm long Fixing method : Tube welded to a drive disc at the motor end and supported by a shaft assembly (item 5) at the bearing end. 5. Single End Barrel Shaft Material : Mild steel bright bar Overall size : 35 mm diameter x 350 mm long Fixing method : Welded to barrel discs 6. Motor Manufacturer : Ellard Type : JM500 Speedsafe Operator, 50Hz/230V, and supplied with gear & drive chain mechanism, mounting plate (item 7) and bearing (item 8). Fixing method : Fixed to mounting plate (item 7) using 3 no. M8 welded studs with steel washers and nyloc nuts.

15 Page 15 of 36 Item Description 7. Motor Mounting Plate Material : Mild steel plate Thickness : 6 mm Overall size : 460 mm long x 200 mm wide Fixing method : Fixed to end plate (item 1) using 4 no. M8 x 25 mm long hex hd. setscrews with steel washer and nyloc nut. 8. Bearing Type : 35 mm flange bearing unit Material : Steel/cast iron Fixing method : Fixed to end plate (item 1) using 4 no. M12 hex head setscrews with hex nut. 9. Shutter Curtain Material : Traditional scrolled galvanised steel interlocking laths 76 mm. Alternate laths fitted with cast steel end locks using steel pop rivets. Thickness : 0.9 mm Section size and profile of laths : See Figure 3 Overall curtain size : 2570 mm wide (not including end locks) x 2900 mm height. Fixing method : Top lath fixed to barrel (item 4) using 6 no. M6 x 20 mm long setscrews at 410 mm centres into 6 mm thick x 50 mm x 20 mm tapping plates. 10. Bottom Rail Material : Galvanised mild steel rolled T section Thickness : 1.6 mm Overall section size : 75 mm wide x 70 mm high x 2570 mm long Fixing method : Interlocked to the bottom of the shutter curtain and secured with end locks. 11. Barrel Casing Material : Pre galvanised mild steel Thickness : 1.2 mm Overall section size : 347 mm wide x 404 mm high x 2800 mm long Fixing method i. to masonry surround : 5 no. M6 expansion bolts c/w steel and fusible washers at 600 mm maximum centres. ii. to end plates : M6 x 16 mm long setscrews c/w steel and fusible washers. 12. Shutter Curtain Stop Plate Material : Mild steel plate Thickness : 6 mm Overall size : 20 mm wide x 120 mm long Fixing method : 2 no. plates pre welded to each guide channel (item 3)

16 Page 16 of 36 Specimen Supporting Construction Masonry Bricks Density : 1600 kg/m 3 Strength : 50 N/mm 2 Thickness : mm Length : 215 mm Height : 73 mm Brick configuration : Half lap, stretcher bond with no finishes Mortar Material : Cement, sand Mix ratio : 1 : 4

17 Page 17 of 36 Instrumentation General Furnace Insulation criteria Thermocouples 2 to 6 Thermocouples 7 and 8 Thermocouples 9 to 12 The instrumentation was provided in accordance with the requirements of the Standard. The furnace was controlled so that its mean temperature complied with the requirements of BS EN : 1999 Clause 5.1 using nine plate thermometers, distributed over a plane 100 mm from the surface of the test construction. Thermocouples were provided to monitor the unexposed surface of the specimen, and the output of all instrumentation was recorded at no less than one minute intervals as follows: At five positions on the unexposed surface of the doorset, one approximately at the centre and one at approximately the centre of each quarter section of the doorset. At one position at the head of the doorset and at one position at the base of the doorset. At four other positions to measure the temperature of several components to provide information for assessment purposes. The locations and reference numbers of the various unexposed surface thermocouples and other thermocouples are shown in Figure 6. Integrity criteria Radiation Furnace Pressure Cotton pads and gap gauges were available to evaluate the integrity of the specimen. A water-cooled foil heat-flux meter was used to record the heat radiation from the specimen. The heat flux meter was positioned at a distance of 1 m from the unexposed surface of the specimen. The furnace atmospheric pressure was controlled so that it complied with the requirements of BS EN : Clause 5.2. The calculated pressure differential relative to the laboratory atmosphere at the top of the wall opening was 16.1 (±3) Pa.

18 Page 18 of 36 Test Observations Time All observations are from the unexposed face unless noted otherwise. Mins Secs The ambient air temperature in the vicinity of the test construction was 15ºC at the start of the test with a maximum variation of +9ºC during the test The test commences Slight smoke release is evident from the head of the laths of the specimen The laths begin to discolour as the galvanised coating melts away The bottom rail begins to lift slightly at its mid-span The bottom rail continues to rise at its mid-span Slight cracking sounds are heard, probably due to the expansion of the laths. The bottom rail continues to raise at its mid-span now by approximately 15mm from the threshold. The top 2 laths glow a dull red in colour A cotton pad integrity test is performed over the top left quadrant of the laths. The cotton pad ignites. Cotton pad integrity failure is deemed to occur The gap at the bottom rail is assessed to be approximately 20mm at its unexposed side and 10mm at its exposed side The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria The bottom rail begins to distort back towards the threshold at its mid-span The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria of the test The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria of the test The top lath begins to slump slightly The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria of the test No further significant changes are evident at this time The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria of the test.

19 Page 19 of 36 Time Mins Secs The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria of the test The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria of the test The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria of the test. The test is discontinued at the request of the sponsor.

20 Page 20 of 36 Test Photographs The unexposed face of the doorset after 10 minutes of testing The unexposed face of the doorset after 30 minutes of testing

21 Page 21 of 36 The unexposed face of the doorset after 63 minutes of testing The unexposed face of the doorset after 120 minutes of testing

22 Page 22 of 36 The unexposed face of the doorset after 180 minutes of testing The unexposed face of the doorset after 240 minutes of testing

23 Page 23 of 36 The unexposed face of the doorset after 264 minutes of testing The exposed face of the doorset immediately after the test

24 Page 24 of 36 Temperature and Deflection Data Mean furnace temperature, together with the temperature/time relationship specified in the Standard Time Specified Actual Furnace Furnace Mins Temperature Temperature Deg. C Deg. C

25 Page 25 of 36 Individual and mean temperatures recorded on the unexposed surface of the doorset Time T/C T/C T/C T/C T/C Mean Number Number Number Number Number Temp. Mins Deg. C Deg. C Deg. C Deg. C Deg. C Deg. C

26 Page 26 of 36 Individual temperatures recorded at the head and base of the shutter curtain Time T/C T/C Number Number Mins 7 8 Deg. C Deg. C

27 Page 27 of 36 Individual component temperatures recorded within the doorset Time T/C T/C T/C T/C Number Number Number Number Mins Deg. C Deg. C Deg. C Deg. C

28 Page 28 of 36 Individual component temperatures recorded on the exposed surface of the guide rails Time T/C T/C Number Number Mins Deg. C Deg. C * * Thermocouple malfunction

29 Page 29 of 36 Recorded Radiation Intensity Time Radiation Intensity Mins At 1M kw/m * * Radiometer removed from Specimen

30 Page 30 of 36 Graph showing recorded furnace pressure at a position approximately 300 mm above the head of the wall aperture Pressure - Pa Time - Minutes

31 Page 31 of 36 Graph Showing Mean Furnace Temperature, Together with the Temperature/Time Relationship Specified in the Standard Temperature - Deg. C Specified Furnace Temperature Deg. C Actual Furnace Temperature Deg. C Time - Minutes

32 Page 32 of 36 Graph showing the mean temperature recorded on the unexposed surface of the doorset Temperature - Deg. C Time - Minutes

33 Page 33 of 36 Performance Criteria and Test Results Integrity It is required that the specimens retain their separating function, without: causing ignition of a cotton pad when applied permitting the penetration of a gap gauge as specified in BS EN : 2008 sustained flaming on the unexposed surface These requirements were satisfied for the periods shown below: Sustained flaming Gap gauge Cotton Pad 264 minutes* 264 minutes* 23 minutes *The test duration. The test was discontinued after a period of 264 minutes. Insulation The mean temperature rise of the unexposed surface shall not be greater than 140 C and that the maximum temperature rise shall not be greater than 180 C (except on the door frame, where the maximum temperature rise shall not exceed 360 C). Insulation failure also occurs simultaneously with integrity failure as specified in BS EN : These requirements were satisfied for the period shown below: 3 minutes Ongoing Implications Limitations 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 BS EN : 1999, and where appropriate BS EN :1999. 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. Annex A of BS EN : 1999, provides guidance information on the application of fire resistance tests and the interpretation of test data. 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. Review The specification and interpretation of fire test methods are the subject of ongoing development and refinement. Changes in associated legislation may also occur. For these reasons it is recommended that the relevance of test reports over five years old should be considered by the user. The laboratory that issued the report will be able to offer, on behalf of the legal owner, a review of the procedures adopted for a particular test to ensure that they are consistent with current practices, and if required may endorse the test report.

34 Page 34 of 36 Conclusions Evaluation against objective A specimen of an uninsulated rolling shutter doorset has been subjected to a fire resistance test in accordance with BS EN : 2008, Fire resistance tests for door and shutter assemblies, BS EN : 1999, General requirements and BS EN : 1999, Alternative and additional procedures. The evaluation of the doorset against the requirements of BS EN : 2008 showed that it satisfied the requirements for the periods detailed below. Integrity performance Insulation performance Sustained flaming Gap gauge Cotton Pad 264 minutes* 264 minutes* 23 minutes 3 minutes *The test duration. The test was discontinued after a period of 264 minutes.

35 Page 35 of 36 Field of Direct Application General Materials and Constructions General The field of direct application of results is restricted to governing the allowable changes to the test specimen following a successful fire resistance test. These variations can be introduced automatically without the need for the sponsor to seek additional evaluation, calculation or approval. Unless otherwise stated in the following text the construction of the door assemblies shall be the same as that tested. The number of leaves and the mode of operation (e.g. sliding, swinging, single action or double action) shall not be changed. For uninsulated shutters the material thicknesses may be increased by up to 50% but it shall not be reduced beyond acceptable steel industry tolerances. The material thickness of side guides and barrel carrying end plates may be increased by up to 50% but it shall not be reduced beyond acceptable steel industry tolerances. The clearance between the end of the shutter laths and the inside faces of the guides shall be increased in proportion to the increase in width of the laths (see Figure 32 of BS EN : 2008). The tightness (overlap) between the shutter curtain and the vertical guides shall not be reduced for size decreases, but shall be increased proportionally for size increases. Decorative Finishes Frames Permissible size variations General Asymmetrical door assemblies General Paint finishes are acceptable and may be added to the doorset. The number of fixings used to attach each doorset to supporting constructions may be increased but shall not be decreased and the distance between fixings may be reduced but shall not be increased. Doors of sizes different from those of tested specimens are permitted within certain limitations but variations are dependent on the product type and the length of time that the performance criteria are fulfilled. BS EN states that for separating elements required to be fire resisting from both sides, two specimens shall be tested (one from each direction) unless the element is fully symmetrical. However, in some cases it is possible to develop rules whereby the fire resistance of an asymmetrical door assembly tested in one direction can apply when the fire exposure is from the other direction. The possibility to develop such rules increases if the consideration is limited to certain types of door assembly and on the criteria being applicable, e.g. integrity only doors. The following rules represent the minimum level of common agreement which shall be followed. The rationale behind the rules is given in Annex C of BS EN : 2008.

36 Page 36 of 36 Specific rules Supporting constructions general The doorset was asymmetrical and was tested such that it was mounted with its barrel and supporting components on the exposed face of the wall. The doorset conformed with the specific rules given in of BS EN : 2008 which gives details of the applicability of the test results of doorsets tested in one direction to cover the opposite opening direction. Therefore the results are applicable to doorsets exposed from the opposite direction. The fire resistance of a door assembly tested in one form of standard supporting construction may or may not apply when it is mounted in other types of construction. Generally, the rigid and flexible types are not interchangeable and rules governing the direct application within each group are given in to of BS EN : However, in some cases it is possible for the result of a test on a particular type of door assembly tested in one form of standard supporting construction to be applicable to that door assembly when mounted in a different type of standard supporting construction. Specific rules governing the situation for hinged and pivoted door assemblies are given in of BS EN : The rationale behind the rules is given in Annex C of that standard.