INTERTEK Fire Resistance Floor Panel

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This report is for the exclusive use of Intertek's Client and is provided pursuant to the agreement between Intertek and its ClientIntertek's responsibility and liability are limited to the terms and conditions of the agreement. Intertek assumes no liability to any

party, other than to the Client in accordance with the agreement, for any loss, expense or damage occasioned by the use of thireport. Only the Client is authorized to copy or distribute this report and then only in its entirety. Any use of the Intertek name oone of its marks for the sale or advertisement of the tested material, product or service must first be approved in writing byIntertek. The observations and test results in this report are relevant only to the sample tested. This report by itself does not implythat the material, product, or service is or has ever been under an Intertek certification program.

REPORT NUMBER: 3083303SAT Rev.1

ORIGINAL ISSUE DATE: March 31, 2008REVISED DATE: January 8, 2009

EVALUATION CENTER16015 Shady Falls Road

Elmendorf, TX 78112(voice) 210-635-8100(fax) 210-635-8101

www.intertek-etlsemko.com

RENDERED TO

Emmedue S.P.AVia Toniolo 39/b61030-Fano, Italy

PRODUCT EVALUATED: A Load-bearing Floor-Ceiling of PSM80 PanelsEVALUATION PROPERTY: Fire Resistance

TE

STREPORT

Report of Testing a load-bearing floor-ceiling assembly madefrom PSM80 Panels for compliance with the applicable

requirements of the following criteria: ASTM E119-07a, FireTests of Bui lding Construction and Materials


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Emmedue S.P.A. January 8, 2009Project No. 3083303SAT Rev.1 Page 2 of 59

1 Table of Contents

ITEM PAGE

1 Table of Contents 2

2 Introduction 3

3 Test Samples 3

4 Testing and Evaluation Methods 3

5 Testing and Evaluation Results 8

6 Conclusions 10

Appendices

Appendix A: Construction Drawings and TC Layout 12

Appendix B: Temperature Data 15

Appendix C: Photographs 25

Revision Summary / Last Page of Report 59


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2 Introduction

Intertek Testing Services NA (Intertek) has conducted testing for Emmedue S.P.A, on a load-bearing floor-ceiling assembly constructed from PSM80 panels, to evaluate its fire resistance.

Testing was conducted in accordance with ASTM E119-07a, Fire Tests of Building Constructionand Materials. This evaluation was completed December 7, 2007.

3 Test Samples

3.1. SAMPLE SELECTION

Samples were randomly selected on July 1, 2007 by Intertek representative Matt Lansdowne,EIT, at the Emmedue S.P.A manufacturing facility, located at Via Toniolo 39/b, Z.I. Bellocchi,61032 Fano (PU), Italy. Samples were received at Intertek San Antonio on August 28, 2007.

The subject test specimens are traceable samples selected from the manufacturer's facility.Intertek selected the specimens and has verified the composition, manufacturing techniquesand quality assurance procedures.

3.2. SAMPLE AND ASSEMBLY DESCRIPTION

The 13x19 floor-ceiling assembly was constructed from five 4x14 panels. The lengths of thepanels were cut down to 12 7 with four panels keeping their original 4 width and one panelbeing cut to 31 wide. The panels were cut down and placed inside a steel frame perimeter ontop of a 3 wide x 1 thick x 19 long board to give a nominal 1 space at the bottom of theassembly for the mortar. A nominal 2 gap was left between the steel perimeter and the panels

prior to pouring the mortar. The panels were butted together, giving an approximate 1 overlapof their wire mesh, and tied at the joints with wire spaced 8 o.c. along the 13 length of thepanels. The floor-ceiling assembly was 7 thick with a 4 foam polystyrene core that containedelectro-welded steel wire meshes made of galvanized drawn steel wires placed on both sides ofthe polystyrene sheet and connected by joints of the same material. Mortar with a mix ratio byweight of concrete to sand to water was 100 pounds of PortlandCement to 280 pounds ofsand to 5.0 gallons of water mixed to be sprayed on the fire side of the polystyrene sheet. Themortar was applied to a nominal 1 thickness on the fire side of the floor-ceiling. Concrete withthe mixture found in report 3083303SAT-004 Rev.1 on page 64 was applied to the unexposedside of the assembly to a nominal 2 thickness with a nominal 2 cap around the perimeter of theassembly.

4 Testing and Evaluation Methods

Test Furnace

The 12 ft x 18 ft x 7 ft deep horizontal test furnace is designed to allow the test specimen to beuniformly exposed to the specified time-temperature conditions. It is fitted with 12 symmetrically-located premixed propane/air gas burners, located 6 feet below the top ledge of the furnace,


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and designed to allow an even heat flux distribution across the under surface of a horizontal testspecimen. Furnace pressures may be maintained at any value from +0.5 in. W.C. to -0.05 in.W.C. at the exposed surface of the test article. The burners, when fully fired, will deliver 20MBtu/hr total heat input. The resulting fire exposure consisted of non-impinging flamesprojecting upwards from the bottom of the furnace such that the test specimens are completelysurrounded by flames. Baffles are installed directly in front of each burner nozzle to disperse

the flame and prohibit direct impingement. The furnace consists of a structural steel frame,lined with sheet metal and insulated with a six-inch thick layer of ceramic fiber. One wall of thefurnace contains a personnel door to allow access to the inside with the test article in place.

During the performance of a fire exposure test, the furnace temperatures are monitored everysix seconds and displayed for the furnace operator to allow control along the specifiedtemperature curve. All data is also saved to hard disk every sixty seconds.

The furnace interior temperature during a test is controlled such that the area under thetimetemperature curve is within 10% of the corresponding area under the standardtimetemperature curve for 1 hour or less tests, 7.5% for those less than 2 hours and 5% forthose tests of 2 hours or more duration.

The mortar and concrete cylinder tests were performed for the sample within 48 hours of the fullscale fire resistance test. Refer to report number 3083303SAT-008 for all the test results.

Compressive Strength Tests were performed by Raba Kistner Consultants, Inc, located at12821 W. Golden Lane, San Antonio, TX 78269-0287

ASTM E119-07a Fire Tests of Building Const ruct ion and Materials

"The performance of walls, columns, floors, and other building members under fire exposureconditions is an item of major importance in securing constructions that are safe, and that are


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not a menace to neighboring structures nor to the public. Recognition of this is registered in thecodes of many authorities, municipal and other. It is important to secure balance of the manyunits in a single building, and of buildings of like character and use in a community; and also topromote uniformity in requirements of various authorities throughout the country. To do this it isnecessary that the fire-resistive properties of materials and assemblies be measured andspecified according to a common standard expressed in terms that are applicable alike to a

wide variety of materials, situations, and conditions of exposure.

Such a standard is found in the methods that follow. They prescribe a standard exposing fire ofcontrolled extent and severity. Performance is defined as the period of resistance to standardexposure elapsing before the first critical point in behavior is observed. Results are reported inunits in which field exposures can be judged and expressed.

The methods may be cited as the "Standard Fire Tests," and the performance or exposure shallbe expressed as "2-h," "6-h," "1/2-h," etc.

When a factor of safety exceeding that inherent in the test conditions is desired, a proportionalincrease should be made in the specified time-classification period.

The ASTM E119 test procedure is identical or very similar to the following standard testmethods:

UL 263UBC 7-1

NFPA 251ANSI A2.1ULC S101

The analogous test standard in the International Organization of Standardization (ISO), ISO 834Fire-resistance Tests Elements of Building Construction, is very similar to the above U.S. testmethods. Its exposure curve, as well as the method used to measure temperatures within the

furnace result in a slightly less severe temperature exposure than the E119 test for the first twohours. The ISO 834 test requires a slightly greater positive pressure within the furnace. Forthose reasons, the E119 test can be considered to be slightly more severe for tests of 2 hduration or less, only if the test article is not likely to be affected by a higher furnace pressure.(BS 476 Pt 20 Fire tests on building materials and structures is virtually identical to the ISO 834test method, as is the new CEN standard, EN 1363-1.)

1. Scope1.1 The test methods described in this fire-test-response standard are applicable to assembliesof masonry units and to composite assemblies of structural materials for buildings, includingbearing and other walls and partitions, columns, girders, beams, slabs, and composite slab andbeam assemblies for floors and roofs. They are also applicable to other assemblies and

structural units that constitute permanent integral parts of a finished building.1.2 It is the intent that classifications shall register comparative performance to specific fire-testconditions during the period of exposure and shall not be construed as having determinedsuitability for use under other conditions or after fire exposure.1.3 This standard is used to measure and describe the response of materials, products, orassemblies to heat and flame under controlled conditions, but does not by itself incorporate allfactors required for fire hazard or fire risk assessment of the materials, products or assembliesunder actual fire conditions.


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1.4 These test methods prescribe a standard fire exposure for comparing the test results ofbuilding construction assemblies. The results of these tests are one factor in assessingpredicted fire performance of building construction assemblies. Application of these test resultsto predict the performance of actual building construction requires the evaluation of testconditions.1.5 The values stated in inch-pound units are to be regarded as the standard. The values given

in parentheses are for information only.1.6This standard does not purport to address all of the safety concerns, if any, associated withits use. It is the responsibility of the user of this standard to establish appropriate safety andhealth practices and determine the applicability of regulatory limitations prior to use.1.7 The text of this standard references notes and footnotes which provide explanatory material.These notes and footnotes (excluding those in tables and figures) shall not be considered asrequirements of the standard.

4. Signif icance and Use4.1 This test method is intended to evaluate the duration for which the types of assembliesnoted in 1.1 will contain a fire, retain their structural integrity or exhibit both propertiesdependent upon the type of assembly involved during a predetermined test exposure.

4.2 The test exposes a specimen to a standard fire controlled to achieve specified temperaturesthroughout a specified time period. When required, the fire exposure is followed by theapplication of a specified standard fire hose stream. The test provides a relative measure of thefire-test-response of comparable assemblies under these fire exposure conditions. Theexposure is not representative of all fire conditions because conditions vary with changes in theamount, nature and distribution of fire loading, ventilation, compartment size and configuration,and heat sink characteristics of the compartment. Variation from the test conditions orspecimen construction, such as size, materials, method of assembly, also affects the fire-test-response. For these reasons, evaluation of the variation is required for application toconstruction in the field.4.3 The test standard provides for the following:4.3.1 For walls, partitions and floor or roof assemblies:

4.3.1.1 Measurement of the transmission of heat.4.3.1.2 Measurement of the transmission of hot gases through the assembly, sufficient to ignitecotton waste.4.3.1.3 For load bearing elements, measurement of the load carrying ability of the test specimenduring the test exposure.4.3.2 For individual load bearing assemblies such as beams and columns:4.3.2.1 Measurement of the load carrying ability under the test exposure with some consid-eration for the end support conditions (that is, restrained or not restrained).4.4 The test standard does not provide the following:4.4.1 Full information as to performance of assemblies constructed with components or lengthsother than those tested.4.4.2 Evaluation of the degree by which the assembly contributes to the fire hazard by

generation of smoke, toxic gases, or other products of combustion.4.4.3 Measurement of the degree of control or limitation of the passage of smoke or products ofcombustion through the assembly.4.4.4 Simulation of the fire behavior of joints between building elements such as floor-wall orwall-wall, etc., connections.4.4.5 Measurement of flame spread over surface of tested element.4.4.6 The effect of fire endurance of conventional openings in the assembly, that is electricalreceptacle outlets, plumbing pipe, etc., unless specifically provided for in the construction


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tested."

The fire exposure is controlled to conform to the standard time-temperature curve shown inFigure 1, as determined by the table below:

24021018015012090603000

250

500

750

1000

1250

1500

1750

2000

2250

ASTM E119 Time-Temperature Curve

Time (min)

Temperature(F)

Time(min)

05

1020306090

120180

240

Temperature(F)

6810001300146215501700179218501925

2000

Temperatures of Unexposed Surfaces

Temperatures of unexposed surfaces are monitored using 24 gage, Type K thermocouplesplaced under 6 in. x 6 in. x 0.4 in. thick dry, felted pads as described in the standard.Temperature readings are taken at not less than nine points on the surface, at intervals not

exceeding 1.0 minute. The temperature on the unexposed surface of a test specimen duringthe test is taken to be the average value of all unexposed thermocouples.

Fire Endurance Test

The fire exposure is continued on the specimen with its applied load if applicable, until failureoccurs, or until the specimen has withstood the test conditions for the desired fire endurancerating.

Correction Factor

When the indicated resistance period is 1/2 h or over, determined by the average or maximumtemperature rise on the unexposed surface or within the test sample, or by failure under load,, a

correction shall be applied for variation of the furnace exposure from that prescribed, where itwill affect the classification, by multiplying the indicated period by two thirds of the difference inarea between the curve of average furnace temperature and the standard curve for the firstthree fourths of the period and dividing the product by the area between the standard curve anda base line of 68F (20C) for the same part of the indicated period, the latter area increased by3240Fmin to compensate for the thermal lag of the furnace thermocouples during the first partof the test. For a fire exposure in the test higher than standard, the indicated resistance periodshall be increased by the amount of the correction. For a fire exposure in the test lower than


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standard, the indicated resistance period shall be similarly decreased for fire exposure belowstandard. The correction is accomplished by mathematically adding the correction factor, C, tothe indicated resistance period.

The correction can be expressed by the following equation:

C =2 I(AAs)3 (As+L)

where:

C = correction in the same units as I,I = indicated fire-resistance period,

A = area under the curve of indicated average furnace temperature for the first threefourths of the indicated period,

As = area under the standard furnace curve for the same part of the indicated period,

andL = lag correction in the same units as A and As (54Fh or 30Ch (3240Fmin or

1800Cmin))

5 Testing and Evaluation Resul ts

5.1. RESULTS AND OBSERVATIONS

The floor-ceiling was placed on the laboratorys large scale horizontal furnace, unrestrained, onDecember 7, 2007. The ambient temperature at the start of the test was 68F, with a relativehumidity of 93%. At 9:25AM., the furnace was fired and the standard ASTM E119 time-temperature curve was followed for a period of 60 minutes. A live load of 10 psf was applied tothe floor for the duration of the fire resistance test. Throughout the fire test, the pressuredifferential between the inside of the furnace (measured at a point 12 below the test sample)and the laboratory ambient air was maintained at -0.01 inches of water column, which resultedin a slightly negative pressure at the test article.

Observations made during the test are as follows:

Time (min:sec) Observation

0:00 The test was started at 9:25 AM.

13:00 The first layer of mortar started falling from the exposed side of the sample.

16:00 Mortar continued falling from the exposed side of the sample.17:00 Moisture escaping from the slab was collecting on the unexposed side of the


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assembly.

38:00 Small stress cracks began forming at the corners on the unexposed side ofthe assembly.

43:00 Escaping gas on the exposed side of the sample began flaming.

60:00 The test was terminated.

The floor/ceiling withstood the fire resistance test without passage of flame or gases hot enoughto ignite cotton waste, for the 60-minute test, at which time the furnace was extinguished.Transmission of heat through the assembly during the fire endurance test did not raise theaverage temperature on the unexposed surface more than 250F, nor any individualtemperature more than 325F. The assembly withstood the fire test without passage of flame orgases hot enough to ignite cotton waste.

During the fire test, the floor/ceiling was measured for deflection at three points along itscenterline: Measurements were made from a taut string that was stretched across the surface ofthe sample.

Time

(min)

Position

#1 (in.)

Position

#2 (in.)

Position

#3 (in.)

Loaded 0 0 0

7 1 1 1

14 1-1/2 1-3/4 1-1/4

22 1-3/4 2-1/4 1-1/2

30 2 2-3/4 1-3/4

37 2-1/2 3 2-1/8

45 2-1/2 3-1/4 2-1/8

53 2-3/4 3-1/2 2-1/2

58 2-3/4 3-1/2 2-1/2


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In accordance with the E119 test standard, a calculation for any correction to the indicated fire

resistance period was done. The correction factor was then mathematically added to theindicated fire resistance period, yielding the fire resistance period achieved by this specimen:

ITEM DESCRIPTIONTEST

VALUE

C correction factor -0.21 minutes-13 seconds

I indicated fire-resistance period 60 minutes

A area under the curve of indicated averagefurnace temperature for the first three fourthsof the indicated period

57961 (Fmin)

As area under the standard furnace curve for thesame part of the indicated period 58288 (Fmin)

L lag correction 3240

FIRE RESISTANCE PERIODACHIEVED BY THIS SPECIMEN ==>

60 minutes

Note: The standard specifies that the fire resistance be determined to the nearest integralminute. Consequently, if the correction factor is less than 30 seconds, and the test specimen metthe criteria for the full indicated fire resistance period, no correction is deemed necessary.

Listings and plots of the furnace control temperatures and specimen unexposed surfacetemperatures may be found in Appendix B. A photographic documentation of the test has beenincluded in Appendix C.

6 Conclusion

Intertek Testing Services NA (Intertek) has conducted testing for Emmedue S.P.A. A load-bearing, 7 thick, floor/ceiling assembly produced, assembled and tested as described herein,successfully met the conditions of acceptance as outlined in ASTM Method E119-07a Fire Tests

of Building Construction and Materials for a fire endurance rating of 1 hour, while maintaining alive load of 10 psf. This evaluation was completed November 20, 2007.

The conclusions of this test report may be used as part of the requirements for Intertek productcertification. Authority to Mark must be issued for a product to become certified.


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INTERTEK TESTING SERVICES NA

Reported by: _____________________Joseph ZatopekEngineer

Reviewed by: _____________________Mike DeyProject Manager, Fire Resistance


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APPENDIX AConstruction Drawings

AndThermocouple Layout


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APPENDIX BTemperature Data


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APPENDIX CPhotographs


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REVISION SUMMARY

DATE SUMMARYJanuary 8, 2009 Revised Project No. to 3083303SAT, throughoutJanuary 8, 2009 Revised header information to match report cover and add [age

numbers

January 8, 2009 Revised reference to Project No. 3083303-4 (pg.3) to 3083303SAT-04 Rev.1

January 8, 2009 Revised reference to Project No. 3083303-4 (pg.4) to 3083303SAT-08 Rev.1

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