Exova Warringtonfire Holmesfield Road Warrington WA1 2DS United Kingdom T : +44 (0) 1925 655 116 F : +44 (0) 1925 655 419 E : warrington@exova.com W: www.exova.com Title: Fire resistance test in accordance with BS EN 1634-1: 2008 on an uninsulated, face fixed rolling shutter doorset Report No: 308897 Prepared for: Bolton Gate Co. Ltd Waterloo Street, Bolton, BL1 2SP. Date: 28 th October 2011 Notified Body No: 0833 0249 Registered Office: Exova (UK) Ltd, Lochend Industrial Estate, Newbridge, Midlothian EH28 8PL United Kingdom. Reg No.SC 70429
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 1634-1: 2008. 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 2011. *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 Extracts or abridgements of reports shall not be published without permission of Exova Warringtonfire.
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
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
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 1634-1: 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 1363-1: 1999, Fire resistance tests - Part 1: General requirements and BS EN 1363-2: 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 1634-1: 2008. 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 2011. Exova Warringtonfire was not involved in any selection or sampling procedures of the specimen or any of the components.
Page 6 of 36 Test Specimen Figure 1- General Elevation of Test Specimen from Exposed Face 50 7 2800 casing overall length 200 600mm maximum slot centres A 12 30 3 3 7 450mm maximum slot centres specimen restraint frame GENERAL ELEVATION OF EXPOSED FACE 50 2500 structural opening 100 see detail 'B' FIRE HORIZONTAL SECTION see detail 'C' Do not scale. All dimensions are in mm
Page 7 of 36 Figure 2 Thermocouple Positions Do not scale. All dimensions are in mm
Page 8 of 36 Figure 3 Typical Details of Curtain and Curtain Guide 50 90 M6 expansion bolts SECTION 'A' typ. guide details 70 M6 setscrews 52 9 76 30 FIRE 2 3 9 FIRE 70 75 Detail - item 10 Detail - item 9 10 Do not scale. All dimensions are in mm
Page 9 of 36 Figure 4 Horizontal Section at Motor End Plate 115 65 150 10 M8 expansion bolts 1 9 1 M8 setscrews 4 11 7 6 M8 studs FIRE Do not scale. All dimensions are in mm
Page 10 of 36 Figure 5 Horizontal Section at Bearing End Plate 115 150 10 9 M12 setscrews 4 5 8 1 FIRE 11 Do not scale. All dimensions are in mm
Page 11 of 36 Figure 6 Vertical Section Through Specimen 35 11 452 4 guide angle fixings to structure 2400 structural opening height FIRE 2 3 2500 guide channel 10 Do not scale. All dimensions are in mm
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 8 4 404 35 concrete lintel 9 11 12 FIRE 48 casing fixings to endplate 10 bottom rail fully open position Do not scale. All dimensions are in mm
Page 13 of 36 Figure 8 Vertical Section at Motor Endplate brickwork wall 460 motor plate 6 7 ratchet drive chain concrete lintel 125 150 150 FIRE Do not scale. All dimensions are in mm
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 : 101.6 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.
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)
Page 16 of 36 Specimen Supporting Construction Masonry Bricks Density : 1600 kg/m 3 Strength : 50 N/mm 2 Thickness : 102.5 mm Length : 215 mm Height : 73 mm Brick configuration : Half lap, stretcher bond with no finishes Mortar Material : Cement, sand Mix ratio : 1 : 4
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 1363-1: 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 1363-1: 1999. Clause 5.2. The calculated pressure differential relative to the laboratory atmosphere at the top of the wall opening was 16.1 (±3) Pa.
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. 00 00 The test commences. 01 20 Slight smoke release is evident from the head of the laths of the specimen. 07 00 The laths begin to discolour as the galvanised coating melts away. 10 00 The bottom rail begins to lift slightly at its mid-span. 15 00 The bottom rail continues to rise at its mid-span. 17 00 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. 23 00 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. 26 00 The gap at the bottom rail is assessed to be approximately 20mm at its unexposed side and 10mm at its exposed side. 30 00 The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria. 42 00 The bottom rail begins to distort back towards the threshold at its mid-span. 60 00 The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria of the test. 90 00 The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria of the test. 105 00 The top lath begins to slump slightly. 120 00 The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria of the test. 150 00 No further significant changes are evident at this time. 180 00 The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria of the test.
Page 19 of 36 Time Mins Secs 210 00 The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria of the test. 240 00 The specimen continues to satisfy the sustained flaming and gap gauge integrity criteria of the test. 264 00 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.
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
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
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
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
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 0 20 41 10 678 671 20 781 785 30 842 840 40 885 877 50 918 901 60 945 924 70 968 942 80 988 957 90 1006 970 100 1022 984 110 1036 997 120 1049 1010 130 1061 1017 140 1072 1023 150 1082 1036 160 1092 1036 170 1101 1043 180 1110 1051 190 1118 1060 200 1126 1067 210 1133 1071 220 1140 1077 230 1146 1088 240 1153 1092 250 1159 1107 260 1165 1109 264 1167 1118
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 2 3 4 5 6 Deg. C Deg. C Deg. C Deg. C Deg. C Deg. C 0 20 20 23 21 21 21 10 418 523 389 313 271 382 20 594 603 580 536 522 567 30 647 662 648 590 582 625 40 674 703 694 648 641 671 50 685 693 690 700 678 689 60 721 712 717 668 669 697 70 740 728 736 692 689 717 80 749 734 746 703 699 726 90 755 737 752 709 706 731 100 752 754 756 762 744 753 110 759 760 764 769 754 761 120 767 763 771 777 758 767 130 771 767 772 779 760 769 140 777 768 774 785 765 773 150 771 759 761 775 758 764 160 777 763 764 778 763 769 170 781 766 767 780 768 772 180 785 766 768 784 770 774 190 788 769 771 784 771 776 200 788 771 774 785 772 778 210 791 772 776 785 772 779 220 795 773 778 785 774 780 230 795 775 779 785 774 781 240 796 776 780 786 778 783 250 798 777 779 787 778 784 260 800 778 776 786 778 783 264 801 778 776 790 779 784
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 0 16 21 10 561 209 20 661 388 30 717 558 40 764 618 50 763 677 60 793 653 70 808 679 80 796 690 90 793 699 100 796 745 110 802 760 120 810 769 130 810 775 140 812 778 150 807 774 160 810 778 170 811 782 180 820 784 190 822 787 200 824 788 210 825 792 220 827 793 230 829 796 240 834 798 250 837 799 260 844 801 264 851 802
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 9 10 11 12 Deg. C Deg. C Deg. C Deg. C 0 17 18 17 18 10 391 177 567 536 20 536 408 662 704 30 654 585 719 776 40 725 683 755 833 50 767 726 763 829 60 785 754 810 863 70 816 796 838 890 80 837 823 853 897 90 851 839 861 904 100 866 854 857 902 110 872 862 873 911 120 879 869 882 914 130 884 876 887 920 140 890 882 893 924 150 891 886 886 917 160 892 886 893 922 170 895 889 896 927 180 898 892 896 927 190 900 895 900 932 200 904 898 900 933 210 906 901 908 936 220 909 903 911 939 230 910 905 911 940 240 912 908 913 945 250 914 910 917 948 260 915 911 920 947 264 916 912 916 947
Page 28 of 36 Individual component temperatures recorded on the exposed surface of the guide rails Time T/C T/C Number Number Mins 13 14 Deg. C Deg. C 0 24 20 10 369 387 20 655 640 30 725 708 40 775 773 50 811 775 60 818 799 70 856 842 80 869 855 90 879 866 100 908 889 110 917 904 120 927 915 130 934 921 140 939 928 150 933 927 160 938 921 170 944 925 180 952 929 190 949 932 200 956 932 210 955 936 220 965 937 230 965 938 240 961 * 250 972 260 970 264 971 * Thermocouple malfunction
Page 29 of 36 Recorded Radiation Intensity Time Radiation Intensity Mins At 1M kw/m 2 0 0 10 2.731 20 12.197 30 16.795 40 * 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 264 * Radiometer removed from Specimen
Page 30 of 36 Graph showing recorded furnace pressure at a position approximately 300 mm above the head of the wall aperture 24 22 20 18 16 14 Pressure - Pa 12 10 8 6 4 2 0 0 40 80 120 160 200 240 280 Time - Minutes
Page 31 of 36 Graph Showing Mean Furnace Temperature, Together with the Temperature/Time Relationship Specified in the Standard 1200 1100 1000 900 Temperature - Deg. C 800 700 600 500 Specified Furnace Temperature Deg. C Actual Furnace Temperature Deg. C 400 300 200 100 0 0 40 80 120 160 200 240 280 Time - Minutes
Page 32 of 36 Graph showing the mean temperature recorded on the unexposed surface of the doorset Temperature - Deg. C 840 800 760 720 680 640 600 560 520 480 440 400 360 320 280 240 200 160 120 80 40 0 0 40 80 120 160 200 240 280 Time - Minutes
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 1634-1: 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 1634-1: 2008. 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 1363-1: 1999, and where appropriate BS EN 1363-2:1999. 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 1363-1: 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.
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 1634-1: 2008, Fire resistance tests for door and shutter assemblies, BS EN 1363-1: 1999, General requirements and BS EN 1363-2: 1999, Alternative and additional procedures. The evaluation of the doorset against the requirements of BS EN 1634-1: 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.
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 1634-1: 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 1363-1 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 1634-1: 2008.
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 13.4.2 of BS EN 1634-1: 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 13.5.2 to 13.5.4 of BS EN 1634-1: 2008. 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 13.5.5 of BS EN 1634-1: 2008. The rationale behind the rules is given in Annex C of that standard.