TEST REPORT - Polyfoam...TEST REPORT Fire resistance test of a Polyfoam Polywall ® ICF concrete...

TEST REPORT Fire resistance test of a Polyfoam Polywall

®

ICF concrete load-bearing wall system tested in general accordance with AS 1530.4 -2005. EWFA Report No: 2489001.1 Report Sponsor: Polyfoam Group 32 Dandenong Street Dandenong South VIC 3175 Australia. Test Date: 19

th January 2011

Report No2489001.1 of 22

© Exova Warringtonfire Aus Pty Ltd 2011

DOCUMENT REVISION STATUS

Date Issued Issue No Description

17th February 2011 2489001.1 Initial Issue.

CONTACT INFORMATION

Exova Warringtonfire Aus Pty Ltd - ABN 81 050 241 524

NATA Registered Laboratory

Unit 2, 409-411 Hammond Road Dandenong Victoria 3175 Australia

T: +61 (0)3 9767 1000 F: +61 (0)3 9767 1001

Victoria

Unit 2, 409-411 Hammond Road Dandenong Victoria 3175 Australia

T: +61 (0)3 9767 1000 F: +61 (0)3 9767 1001

New South Wales

Suite 2002a Level 20, 44 Market Street Sydney NSW 2000 Australia

T: +61 (0)2 8270 7600 F: +61 (0)2 9299 6076

Queensland

Northpoint, Unit 12, Level 3 231 North Quay Brisbane QLD 4000 Australia

T: +61 (0)7 3238 1700 F: +61 (0)7 3211 4833

SIGNATORIES

Prepared by Reviewed by

Steven Halliday

Chad McLean

On behalf of Exova Warringtonfire Aus Pty Ltd

GENERAL CONDITIONS OF USE

This report may only be reproduced in full without modifications by the report applicant only. Copies, extracts or abridgments of this report in any form shall not be made distributed or published by other organisations or individuals without the permission in writing from a Director of Exova Warringtonfire Aus Pty Ltd.



CONTENTS

1 CONSTRUCTION DETAILS 4 Test Assembly 4 Test Specimen 4 Assembly and Installation Methods 4 Orientation 4

2 SCHEDULE OF COMPONENTS 5

3 TEST PROCEDURE 7 Statement of compliance 7 Variation to Test method 7 Pre-test conditioning 7 Sampling / Specimen Selection 7 Ambient Temperature 7 Applied Load 7 Test Duration 7 Instrumentation and Equipment 7

4 TEST MEASUREMENTS 8 Furnace Temperature and Pressure Measurements 8 Specimen Temperatures 8 Observations 8 Deflections 8

5 TEST RESULTS 8

6 APPLICATION OF TEST RESULTS 8 Test Limitations 8 Variations from the Tested Specimens 8 Uncertainty of measurement 8

APPENDIX 1 DRAWINGS OF TEST ASSEMBLY 9

APPENDIX 2 TEST OBSERVATIONS 12

APPENDIX 3 DIRECT FIELD OF APPLICATION 14

APPENDIX 4 INSTRUMENTATION 14

APPENDIX 5 TEST DATA 15 A 5.1 Furnace Temperature 15 A 5.2 Furnace Pressure 16 A 5.3 Specimen Temperatures 17 A 5.4 Deflection Measurements 20

APPENDIX 6 PHOTOGRAPHS 21



1 CONSTRUCTION DETAILS

TEST ASSEMBLY

The test assembly comprised a nominal 3000 mm wide × 3100 mm high × 245 mm thick load-bearing reinforced concrete wall system.

TEST SPECIMEN

The test specimen was constructed from 1200mm long × 300mm high × 245mm thick Polyfoam Polywall

® ICF (Insulated Concrete Form) blocks. The 60mm thick polystyrene faces

of the blocks were spaced apart by PP connecting bridges creating a 125mm wide cavity between them that was backfilled with concrete. The exposed face of polystyrene was removed prior to testing.

The wall was restrained at the top and base while the east and west vertical edges were free from restraint. Further details are provided in Figures A1.1 to A1.3 and the Schedule of Components.

ASSEMBLY AND INSTALLATION METHODS

The Polywall® system was assembled on the 10th of November 2010 by the test sponsor under the supervision of Exova Warrington Fire representatives. The concrete was poured on the 23

rd of November 2010 by the test sponsor under the supervision of Exova Warrington Fire

representatives.

ORIENTATION

The test specimen was exposed from the side where the polystyrene was removed.



2 SCHEDULE OF COMPONENTS

ITEM NO.

ITEM DESCRIPTION

1

Product Polyfoam Polywall® 201

Material Spacel EPS Expandable Polystyrene Fire Retardant Modified Grade

Size Each block was 1200mm wide × 300mm high × 245mm thick

Each face of the block was 60mm thick.

Mass 0.5576 kg/unit (measured)

Density 26.76 kg/m3 (measured)

Location/ Fixing

Stacked to form the exposed and unexposed faces of the wall system. Exposed face removed prior to test exposing bridges and concrete.

2

Product Polyfoam 204 Connecting Bridge

Material Polypropylene (Moplen EP301G)

Size 48mm wide × 198mm high × 212mm deep

Mass 0.1429 kg (measured)

Location 150-off bridges were located in a 200mm wide × 300mm high grid throughout the wall system extending from the exposed side to the unexposed side through the concrete.

3

Product Polyfoam 202 Starter Bridge

Material Polypropylene (Moplen EP301G)

Size 48mm wide × 80mm high × 210mm deep

Mass 0.0534 kg (measured)

Location 15-off bridges across the bottom of the wall system extending from the exposed to the unexposed side through the concrete.

4

Product N12 Reinforcement Bar

Material High-yield tempcore steel

Mass 0.8668 kg/m (measured)

Location/ Fixing

Formed into a nominal 300mm grid with horizontal members locked into bridges (Items 2 and 3) and vertical members secured to horizontal members using 1.5mm diameter metal wire ties.

5

Product Starting Channel 209

Material 0.55 bmt galvanised steel

Size 62mm deep × 37mm high

Mass 0.5112 kg/m (measured)



ITEM NO.

ITEM DESCRIPTION

Location Placed on bottom edge of exposed Polywall® between

blocks and cement sheet. Secured to cement sheet using expanding foam (Item 6)

6

Product Illbruck PU 010 EIFS Adhesive Foam

Material Polyurethane Expanding Foam

Location Between Polywall® horizontal and vertical joins.

7

Product Concrete with Sika ViscoCrete 10

Material Concrete with an average strength of 35.5 MPa at 28 days curing

Density 2,253 kg/m3 (measured on day of test)

Moisture content

3.04% (measured by mass)

Location Filling 125mm wide cavity between exposed and unexposed Polywall® from cement sheet base up to head of frame.

8

Product Cement Sheet

Size 300mm deep × 4.5mm thick

Density 1,387 kg/m3 (measured)

Location At base of wall system, full width.

Perimeter Construction

9 Perimeter blockwork

390mm high × 90mm wide × 190mm deep solid concrete blocks were installed to the east and west vertical free edges of the specimen.

10 Free-edge seal

25mm thick ceramic fibre sealing to the east and west vertical edges.

11 Frame Steel furnace restraint frame

12 Loading jacks

250mm from each end and 500mm spacing in between.



3 TEST PROCEDURE

STATEMENT OF COMPLIANCE

The test was performed in general accordance with the requirements of AS1530.4-2005 section 2 & 3 subject to the variations listed below.

VARIATION TO TEST METHOD

The pressure was above that allowable by the standard during the 10 to 20 minute test period. This variation is unlikely to have had any adverse affect on the test as there we no through gaps observed during the test. The furnace temperature was below the required curve at the start of test and above the curve for the later part of the test. A singe sensor was 100 degrees or more below the required furnace temperature from 14 minutes to 45 minutes and after 120 minutes the average furnace temperature was above the required curve from that point until the end of the test. The overall severity of the test was calculated to be within the 2.5% exposure. The results of this test should therefore be used with caution and are offered for the information of others.

PRE-TEST CONDITIONING

The construction of the wall was finished on the 23rd

November 2010 and given 57 days to cure. The exposed face of Polywall® blocks were removed on the 18th January 2010. During this period the test specimen was subject to normal laboratory temperatures and conditions.

SAMPLING / SPECIMEN SELECTION

The laboratory was not involved in the sampling or selection of the test specimen for the fire resistance test.

AMBIENT TEMPERATURE

The ambient temperature at the start of the test was approximately 24°C and varied between 24°C and 31°C during the test.

APPLIED LOAD

The total load applied was 115kN. The load was applied as 6 single point loads at 500mm centres to the bottom edge of the wall.

TEST DURATION

The test duration was 244 minutes.

INSTRUMENTATION AND EQUIPMENT

The instrumentation was provided in accordance with AS 1530.4-2005 and as detailed below:

The furnace temperature was measured by 6-off mineral insulated metal sheathed Type K thermocouples with wire diameters not greater than 1mm and overall diameter of 3 mm with the measuring junction insulated from the sheath. The thermocouples protruded a minimum of 25 mm from steel supporting tubes.

The non fire side specimen temperatures were measured by Type K thermocouples with wire diameters less than 0.5 mm diameter soldered to 12 mm diameter × 0.2 mm thick copper discs covered by 30 mm × 30 mm × 2.0 mm inorganic insulating pads. The thermocouples positions are described in Table A4.1, and are shown on Figure A4.1 in Appendix 4.

A roving thermocouple was available to measure temperatures at positions that appeared hotter than the positions monitored by the fixed thermocouples.

The furnace pressure was measured at a position 480 mm above the bottom of the wall.

Cotton pads and gap gauges were available during the test to assess the performance under the criteria for integrity.

Deflection measurements were taken from calibrated tapes fixed to the wall using a Telescope Levelling Instrument (Dumpy Level) Model 200B, at the positions shown on Figure A3.2 in Appendix 3.

The load was applied at nominal 500mm centres with hydraulic jacks, via 100mm × 100mm steel pads with pin support conditions. The loading equipment was capable of measuring the load applied within an accuracy of ± 2.5% of the test load.



4 TEST MEASUREMENTS

FURNACE TEMPERATURE AND PRESSURE MEASUREMENTS

Furnace temperature and pressure data are provided in A5.1 and A5.2 respectively in Appendix 5.

SPECIMEN TEMPERATURES

Specimen temperature data is provided in A5.3 and Table A5.1 in Appendix 5.

OBSERVATIONS

A table that includes observations of the significant behaviour of the specimen and details of the occurrence of the various performance criteria specified in AS 1530.4-2005 is provided in Appendix 2. Photographs of the specimen are included in Appendix 6.

DEFLECTIONS

Deflection data is provided in A5.4 in Appendix 5.

5 TEST RESULTS

The specimen achieved the following performance when tested in general accordance with AS 1530.4-2005, Sections 2 & 3 subject to the variations listed in section 3 of this report.

Criteria Result

Structural adequacy Failure at 243 minutes.

Integrity Failure at 243 minutes.

Insulation Failure at 143 minutes.

6 APPLICATION OF TEST RESULTS

TEST LIMITATIONS

The results of this fire test may be used to directly assess fire hazard, but it should be recognized that a single test method will not provide a full assessment of fire hazard under all fire conditions. The results only relate to the behaviour of the specimen of the element of the construction under the particular conditions of the test; they are not intended to be the sole criteria for assessing the potential fire performance of the element in use nor do they necessarily reflect the actual behaviour in fires.

VARIATIONS FROM THE TESTED SPECIMENS

This report details the methods of construction, the test conditions and the results obtained when the specific element of construction described herein was tested following the procedure outlined in AS 1530.4. Any significant variation 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 addressed by this report. It is recommended that any proposed variation to the tested configuration other than as permitted under the field of direct application specified in Appendix 3 should be referred to the test sponsor in the first instance to obtain appropriate documentary evidence of compliance from Exova Warringtonfire Aus Pty Ltd or another Registered Testing Authority.

UNCERTAINTY OF MEASUREMENT

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.



APPENDIX 1 DRAWINGS OF TEST ASSEMBLY

Figure A1.1: Test Specimen Unexposed Face Elevation.



Figure A1.2: Test Specimen vertical section.



Figure A1.3: Test specimen horizontal section.



APPENDIX 2 TEST OBSERVATIONS

The following observations include observations of the significant behaviour of the specimen.

Time

Min Sec Observations

- - 15 minutes loading was completed before the start of the fire resistance test.

0 00 Fire resistance test commenced.

5 30 Smoke evident from perimeter of support frame.

10 20 Audible crack from specimen, likely spalling.

10 34 Additional spalling noise, louder than previous.

11 13 Additional spalling noise, louder again than previous.

15 10 Smoke evident along base of wall in addition to perimeter of support frame. Spalling noises continuing.

21 30 Large amounts of moisture across entire face of specimen.

37 10 Dimple deformations visible in polystyrene in centre and top west regions.

50 00 Large amounts of steam evident across entire face of specimen.

60 00 The specimen continued to maintain structural adequacy, integrity and insulation in accordance with AS 1530.4–2005.

62 20 Further dimple deformations around connecting bridges evident.

70 30 Dimple deformations around connecting bridges visible across majority of specimen surface.

72 10 Concrete visible through large polystyrene deformation approximately 2200mm up and 1200mm in from west edge.

80 20 Concrete visible through multiple deformations localized around vertical polystyrene joins and at connecting bridges at the centre of the specimen.


97 40 Deformations across specimen surface except for bottom row of polystyrene which remains largely unaffected.

103 10 Laser thermometer used on concrete surface through opening in polystyrene 100mm east of thermocouple C2 resulting in a temperature of 100°C.

109 30 A 90 second roving thermocouple test was carried out at the concrete surface through opening in polystyrene 100mm east of thermocouple C2, resulting in a temperature of 103°C.

114 30 Reduction in volume of steam from specimen surface.


135 00 Melting and discolouration of polystyrene evident in top west region.

143 20 A roving thermocouple was applied to exposed concrete at mid-width, 400mm from head of specimen for 120 seconds, resulting in a temperature of 209°C.

Failure on insulation in accordance with AS 1530.4-2005, clause 2.12.3 b).

146 40 500mm wide × 300mm high piece of polystyrene dislodged and suspended from wall 2400mm up and 600mm in from west edge.

147 10 Large section of polystyrene dislodged from wall exposing an approximately 1200mm wide × 600mm high section of concrete at the top of the specimen 600mm in from the west edge. Connecting bridges in region melted and severed at plane of wall.

147 13 500mm wide × 300mm high piece of polystyrene dislodged and suspended from wall 2100mm up and 1200mm in from west edge.

Thermocouples B2 and B3 disconnected.

148 52

Large section of polystyrene dislodged from wall exposing an approximately 1200mm wide × 900mm high section of concrete at the east edge of the specimen 1800mm up. Connecting bridges in region melted and severed at plane of wall.

Thermocouple C2 dislodged.



Time

Min Sec Observations

152 10

Large section of polystyrene dislodged from wall exposing an approximately 600mm wide × 900mm high section of concrete at the west edge of the specimen 1800mm up. Connecting bridges in region melted and severed at plane of wall.

Thermocouples B1 and C1 dislodged.

154 00 Diagonal cracks evident in concrete in top west region.

155 25

Large section of polystyrene dislodged from wall exposing an approximately 1200mm wide × 300mm high section of concrete at the middle of the specimen 1800mm up. Connecting bridges in region melted and severed at plane of wall.

Thermocouples B8, B9 and C3 dislodged.

158 10 Smoke evident from top eastern connecting bridge hole.

159 30 Vertical crack in concrete evident 1300mm in from west edge from the top of the specimen down past mid-height, covered by reaming polystyrene.

162 43

Large section of polystyrene dislodged from wall exposing an approximately 2400mm wide × 1500mm high section of concrete at the west edge of the specimen 300mm up. Connecting bridges in region melted and severed at plane of wall.

Thermocouples B4, C4 and B7 dislodged.

162 58

Large section of polystyrene dislodged from wall. Concrete now exposed full width of specimen from 600mm up to 2700mm.

Thermocouples B5 dislodged.

168 16 Large section of polystyrene dislodged from top east corner of wall.

Crack noted at 159:30 now visible, extending down to 900mm from base of specimen.

170 40 Small amount of smoke evident, originating from connecting bridge hole in bottom west region, third in second up.

172 00 Large bowing of specimen towards furnace evident.

176 22 Deflection at east edge of wall at mid-height measured relative to frame. 140mm from frame to concrete surface.

180 00 The specimen continued to maintain structural adequacy and integrity in accordance with AS 1530.4–2005.

184 20 Glowing evident at multiple connecting bridge holes.

185 49 Section of polystyrene dislodged from mid-width at head of specimen. Majority of concrete now exposed.

Thermocouple B6 dislodged. C5 is only functional thermocouple remaining.

207 02 Through gap to furnace visible at mid-height on east edge of specimen due to the deflection of the wall. No failure of the specimen.

209 31 Section of polystyrene dislodged from top of specimen. Entire face of concrete now exposed except for bottom edge of specimen due to debris.

214 00 Smoke rising across face of specimen. Originating from bottom row of connecting bridge holes.

225 00 Furnace gases evident at east edge of specimen.

227 00 Loud crack heard from specimen.

236 30 Loud crack heard from specimen.

239 20 Pressure increased on loading jacks becoming more frequent.

240 00 The specimen continued to maintain structural adequacy and integrity in accordance with AS 1530.4–2005.

243 56

Section of concrete dislodged over far east loading jack pad causing wall to slide towards the furnace. Failure on structural adequacy in accordance with AS 1530.4-2005, clause 2.12.1 due to collapse of wall

Test terminated.



APPENDIX 3 DIRECT FIELD OF APPLICATION

A 3.1 GENERAL

As the test was not carried out in strict accordance with AS 1530.4-2005 the results of this test are to be used with caution.

APPENDIX 4 INSTRUMENTATION

Figure A4.1: Thermocouple and Deflection Locations on Unexposed Face.

East side

West side

B3

B1

B5 B4

B2

B8

B7

C1

B6

W1

W2

x

y

V3 V1

B9

V2

C2

C4

C3

C5



Table A4.1: Thermocouple and deflection locations

Position T/C Location Description x y

Quarter points

B 1 750 2325 Upper west quarter point. B 2 2250 2325 Upper east quarter point.

B 3 1500 1550 Centre of specimen. B 4 750 775 Lower west quarter point. B 5 2250 775 Lower east quarter point.

Other surface

B 6 1500 3085 15mm from the head of the specimen, at mid width. B 7 100 1550 15mm from the head of the specimen in line with a stud.

B 8 1500 1615 15mm from the junction of a stud and nogging. B 9 1215 1550 100mm from the west free edge at mid-height.

Internal quarter points

C 1 750 2225 Upper west quarter point on concrete. C 2 2250 2225 Upper east quarter point on concrete. C 3 1500 1650 Centre of specimen on concrete.

C 4 750 675 Lower west quarter point on concrete. C 5 2250 675 Lower east quarter point on concrete.

Horiz. Defl. Points

W 1 1500 1500 Centre of specimen at mid-height.

W 2 100 1500 West edge of specimen at mid-height.

Vertical Defl. points

V1 2910 50 Base of the wall to the east.

V2 1500 50 Base of wall at centre. V3 90 50 Base of the wall to the west.

APPENDIX 5 TEST DATA

A 5.1 FURNACE TEMPERATURE

0

200

400

600

800

1000

1200

0 30 60 90 120 150 180 210 240

Time (Minutes)

Te

mp

era

ture

(°C

)

AS 1530.4 Mean Furn Max Furn Min Furn

Figure A5.1: Furnace Temperatures vs. Time.



A 5.2 FURNACE PRESSURE

The results were recorded from a position 480mm above the sill.

Time

(minutes)

Pressure (Pa)

Avg

Time

(minutes)

Pressure (Pa)

Avg

5-10 1 125-130 1

10-15 6 130-135 2

15-20 9 135-140 -1

20-25 2 140-145 -3

25-30 1 145-150 1

30-35 3 150-155 0

35-40 0 155-160 0

40-45 1 160-165 0

45-50 0 165-170 0

50-55 1 170-175 0

55-60 0 175-180 -1

60-65 1 180-185 -1

65-70 1 185-190 -1

70-75 1 190-195 -1

75-80 1 195-200 1

80-85 0 200-205 0

85-90 1 205-210 1

90-95 1 210-215 0

95-100 1 215-220 0

100-105 1 220-225 -1

105-110 2 225-230 0

110-115 1 230-235 -1

115-120 0 235-240 0

120-125 1



A 5.3 SPECIMEN TEMPERATURES

0

10

20

30

40

50

60

70

80

0 30 60 90 120 150 180 210 240

Time (minutes)

Te

mp

era

ture

(d

eg

C)

B1 B2 B3 B4 B5

Figure A5.2: Quarter points. Temperatures vs. Time

0

10

20

30

40

50

60

70

80

0 30 60 90 120 150 180 210 240

Time (minutes)

Te

mp

era

ture

(d

eg

C)

Figure A5.3: Quarter points average. Temperatures vs. Time



0

50

100

150

200

250

300

0 30 60 90 120 150 180 210 240

Time (minutes)

Te

mp

era

ture

(d

eg

C)

C1 C2 C3 C4 C5

Figure A5.4: Inter quarter points. Temperatures vs. Time

0

20

40

60

80

100

120

0 30 60 90 120 150 180 210 240

Time (minutes)

Te

mp

era

ture

(d

eg

C)

B6 B7 B8 B9

Figure A5.5: Other surface. Temperatures vs. Time



Table A5.3: Test Specimen Temperatures

T/C Description2

Temp (°C) at t (minutes) Limit1

t=0 t=30 t=60 t=90 t=120 t=180 t=240 Mins

B1 Upper west quarter point 26 28 36 39 30 # # -

B3 Upper east quarter point 26 24 31 49 37 # # -

B3 Centre of specimen 25 50 44 39 27 # # -

B4 Lower west quarter point 25 29 28 30 27 # # -

B5 Lower east quarter point 25 28 36 39 30 # # -

Average of quarter points and centre of specimen

26 31 34 37 30 # # -

B6 Mid-width at head of specimen 25 28 46 51 46 71 # -

B7 Mid-height 100mm from free edge 25 32 35 37 28 # # -

B8 Mid-width above horizontal join 26 57 43 35 27 # # -

B9 Mid-height next to vertical join 26 28 47 53 30 # # -

C1 Upper west quarter point on concrete 22 52 102 124 163 # # n/a

C2 Upper east quarter point on concrete 22 51 100 118 136 # # n/a

C3 Centre of specimen on concrete 22 76 102 125 173 # # n/a

C4 Lower west quarter point on concrete 22 58 101 112 161 # # n/a

C5 Lower east quarter point on concrete 21 47 100 105 139 222 260 n/a

Notes

1 Limit time is the time to the nearest whole minute, rounded down to the nearest minute, at which the temperature recorded by any thermocouple does not rise by more than 180K above the initial temperature. Limit time for the average of quarter points is the time to the nearest whole minute, rounded down to the nearest minute, at which the average measured temperature does not rise by more than 140K above the initial temperature.

2 Refer to Appendix 4 for locations of thermocouples as only a generic description is included in the table.

# Thermocouple became detached when polystyrene fell away from specimen.. ‘-‘ Under limit column indicates the temperature limit was not exceeded during the test period or up until the

time of integrity or thermocouple failure if a failure occurred. ‘n/a‘ Limit not applicable to this reading



A 5.4 DEFLECTION MEASUREMENTS

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

0 30 60 90 120 150 180 210 240

Time (Minutes)

De

fle

cti

on

(m

m)

W1 (Centre) W2 (Free Edge)

Figure A5.6: Out-of-Plane Deflection of the wall vs. Time. Positive measurements show movement of the wall towards furnace.

0

5

10

15

20

0 30 60 90 120 150 180 210 240

Time (Minutes)

De

fle

cti

on

(m

m)

V1 (Eas t) V2 (Centre) V3 (Wes t)

`

Figure A5.7: Vertical Deflection vs. Time

Positive measurements show movement of the wall upwards.



APPENDIX 6 PHOTOGRAPHS

Figure A6.1: Unexposed face of the specimen prior to the test.

Figure A6.2 Exposed face of the specimen prior to the test.

West side East side

East side West side



Figure A6.3 Unexposed face of test specimen at approximately 242 minutes.

Figure A6.4: Exposed face of the specimen after the termination of the test.

East side West side

East side West side

TEST REPORT - Polyfoam...TEST REPORT Fire resistance test of a Polyfoam Polywall ® ICF concrete...

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