Durasteel projects ref..

Durasteel Valve Enclosures ensure safe operational access at chemical storage facility

Location: Dubai, UAE
Image Gallery Below

DOW Chemical Company's chemical storage facility in Dubai recently identified a safety
requirement to protect the main deluge valves within a chemical storage area from
potential fire and explosions. The valves were located in an open and exposed area
adjacent to the main chemical storage facility.

Tasked with designing 3-sided Durasteel barriers which had to be completely free-
standing, wind resistant and weather-proof, and maintain their integrity within
potentially harsh chemical atmospheric conditions.

Our solution was to build free-standing Durasteel valve protection enclosures
constructed from 80mm x 60mm x 3mm steel channels with a single sheet of Durasteel
bolted to the exterior surface.

Each enclosure was completely installed within 1.5 days from start to finish and now
provides the valves with the blast and fire protection required to ensure continued and
safe operational access in the event of a fire or explosion.

Site supervisor, Louie Aguilar, commented "it was a very fast installation, completed
incredibly quickly by a very professional team and we are extremely pleased with the
outcome."

Gallery

Fire Barriers installed in underground tunnels at Jebel Ali Desalination Plant

Location: Dubai, UAE
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The world's largest desalination plant, the Dubai Electricity and Water Authority (DEWA)
Jebel Ali Desalination Plant located in Dubai, which has an electrical capacity of
2,000MW and purifies around 480 million litres of seawater daily, has recently had
Durasteel extensively installed across the facility by our Middle East division.

Underground tunnels and cable routes run across the entire desalination site,
connecting various buildings at below-ground level and housing cables vital to the
operation of the plant. In order to isolate these tunnels and buildings from any potential
fire hazards, site consultant, Fichtner Consulting Engineers, and main site contractor,
Doosan Heavy Industries and Construction, decided that fire barriers were an essential
requirement in the tunnels in order to maximise safety, contain the spread of fire and
limit the damage caused in the event of a fire occurring.

The requirement was to construct fire barriers to provide effective compartmentation in
the following typical locations:

• Between building basements and cable trenches/tunnels
• Between cable trenches and cable tunnels
• Between trenches and escape routes (ladders) and exits

It was identified that fire barriers were required at 79 separate tunnel locations across
the site in order to effectively isolate a fire occurring within the tunnels, and that each
barrier must provide 2 hour fire protection and withstand high numbers of door
openings and closures every day, in addition to being fully demountable and
relocatable. The size of the fire barrier at each location was designed to be 2.80m wide x
2.20m high, with each fire barrier containing one 2 hour fire rated access door and cut-
out provisions for 6 cable trays on each side of the door to pass through the fire barrier,
with the penetrations being filled with firebat.

Working in harsh underground conditions and with extremely limited manoeuvring
space, each Durasteel barrier was installed in phases, with provisions for cable pulling
and fixing of the access fire doors at a later stage. Erection of each complete barrier,
including the fire doors and penetration sealing, took less than 2 working days from
start to finish.

With the project deemed a success, Durasteel was then specified for use on the same
site as removable generator barriers.

Gallery

Durasteel Ceilings and Cable Turning Box Protect EDF Substation

Location: London, UK
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Throgmorton Street in London is a commercial retail outlet which has recently
undergone a complete refurbishment and an EDF substation installed into the basement
area.

Invicta's Durasteel division were asked to design and install a Durasteel 4 hour fire rated
cable turning box complete with demountable panels to allow access by EDF engineers,
with blastproof fire morter on all penetrations.

Additionally, Invicta also designed and installed 2 independent Durasteel 4 hour fire
rated ceilings to the substation and switch rooms in the basement to protect the offices
above from any explosions originating from the high voltage cables and transformers
located in the rooms. The ceilings were approximately 12m² and 25m² in size and
included a rake detail to deflect any blast out through the louvre in each room.

The entire project was installed from start to finish in 3 weeks.

Related pages: Fireproof Ceilings, Substation Ceiling Fire Protection

Gallery

Demountable EDF Energy Transformer Blast Barriers

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Invicta's Durasteel division has recently completed the installation of 4 demountable
EDF Energy blast barriers to give blast protection of up to 10kN/m² at a substation
demolition site in London.

Due to the limited working space on site, the 4 2.5 tonne Durasteel blast barriers were
fully pre-fabricated and then lifted and secured into position using a crane. The blast
barriers were designed and installed to protect personnel working on the demolition
site from the potential explosions of 4 transformers located in the immediate vicinity.
The barriers are fully demountable within 4 hours in the event of a transformer failing
and the barrier requiring removal in order to allow access to the transformer.

The project was completed from start to finish in less than 5 weeks and the blast
barriers comply with stringent EDF Energy specifications.

Related pages: Transformer Barriers, Blast Walls

Gallery

Transformer Blast Barriers provide blast protection to Fertiliser Plant

Location: UK
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Invicta has recently completed the design and installation of 3 self-supporting
transformer blast barriers at a fertiliser plant in the UK.

The 4.2m x 4.5m blast barriers were designed bespoke to provide 10kN/m² blast
protection, with welded steel bracing supports in order to provide the barriers with
increased stability to cater for the additional blast protection and wind loadings in the
area. The 3 blast barriers were installed in order to prevent a chain blast occurring
should one of the 4 transformers in the area explode.

Installation of all 3 blast barriers was completed in less than 3 weeks, much of which
took place in some of the most severe snow and ice conditions the UK has experienced
in the last century. However, with Invicta's vast experience in designing, project
managing and installing Durasteel, these conditions were overcome and the project was
completed on time.

Related pages: Transformer Barriers, Blast Protection

Gallery

Fireproof Vault Protects Council Records

Location: Staffordshire, UK
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Staffordshire County Council in the UK serves a population of around 800,000 residents
with vital services to the community, including schools, libraries, social services, trading
standards, highways and planning. With all of these services generating large numbers

of paper documents, the Council decided to relocate its document storage facility to a
new, larger warehouse and within it include a fireproof vault for the storage of the most
important documents.

Invicta were asked to design and install a 35m long x 7m wide x 5m tall vault, filled to
capacity with mobile shelving to maximise the vault's storage space. The vault was
engineered and designed to be completely self-supporting, without any internal or
external structural support columns and beams that would normally also require fire
protecting.

Providing industry leading 4 hour fire protection, the vault had air conditioning and a
water leak detection system installed to ensure complete protection from not only fire
but also moisture and water that could also potentially damage the documents inside.

A mantrap lobby was constructed on the outside of the vault's main entry door to
ensure that the ideal ambient temperature could be constantly maintained inside the
vault even when doors were opened. All entry doors were secured with magnetic lock
PIN entry systems to prevent unauthorised access to the vault and sensitive documents.

The vault installation was completed in under 8 weeks before the remaining space in the
warehouse was filled with pallet racking for the storage of the Council's non-sensitive
documents.

Related pages: Fireproof Vault

Gallery

Crown Records Management install custom designed Durasteel fireproof vault

Image Gallery Below

The backing up of business-critical data is widely regarded as being one of the most
important processes a business can do and is a fundamental element of any business
continuity plan. Yet research suggests that up to 75% of backup tapes are kept on-site,
meaning that in the event of a disaster, any business continuity plan that may be in
place will be rendered useless. On average, by the 6th day of a major data loss,
companies experience a 25% loss in daily revenue, and by day 25, this increases to 40%.
It is also estimated that 43% of companies that experience a severe data loss disaster
never re-open.

In response to increasing customer demands driven by the recent surge in both natural
disasters and man-made threats around the world, Crown Records Management
decided to have a custom designed Invicta Durasteel vault installed at one of their
records storage facilities in the UK, providing clients with an industry-leading 4 hour fire
protected facility for the secure storage of their business-critical data tapes and
irreplaceable documents.

The challenge faced by Invicta was to design and integrate the media and document
vault within a large multi-tier racking system without compromising on any loss of space
utilisation within the cube of Crown's building. Invicta's solution was to build a 630
square metre, 4-tier Durasteel vault in one corner of the warehouse to a height of 12
metres. Durasteel is a 4 hour fire rated product that has been tested extensively in the
UK to comply to all relevant parts of BS 476, as well as many international standards
such as Factory Mutual (FM), Underwriters Laboratories Inc (UL), Underwriters

Laboratories Canada (ULC), Det Norske Veritas (DNV), Lloyds Register of Shipping (LRS),
Zulassung, EDF and LUL. In addition to providing superior protection from fire, Durasteel
also provides impact and moisture protection, both of which are essential, but often
overlooked, features for vaults located within buildings surrounded by other structures
that may fall onto it and building services that may fail in the event of a disaster.
Durasteel has also achieved the stringent Certifire approvals and was therefore installed
on the underside of each level of the vault to provide an independent 4 hour fire rated
compartment to each floor level. Mobile shelving was installed on the ground floor,
specifically designed for the optimal storage of over 27,000 data tapes, whilst the upper
three levels of the vault were equipped with racking for the secure storage of over 6000
boxes.

Crown's vault was completed with state-of-the-art climate control and gas suppression
systems in order to regulate a constant environment, and was then smoke and pressure
tested in order to certify its performance.

Related pages: Fireproof Vaults

Gallery

Durasteel Suspended Ceiling Membrane E240 (Fire from Above
and Below)

• Fire resistance: 240 minutes integrity only (Fire attack from above or below)
• Channel (minimum): 80mm x 60mm x 3mm
• Overall depth: 89.5mm
• Weight (nominal): 27kg/m2

Perimeter channels of ceiling membrane fastened to surrounding construction with M10
or M12 allsteel expanding anchors (or equivalent for alternative types of supporting
construction) at 500mm maximum centres.

Primary channels at 1200mm maximum centres, supported from building structure
above the ceiling membrane with steel drop rods at 1.5m centres. Threaded rods pass
through clearance holes in the upper flange of the channels and are fastened with steel
hexagon full nuts.

Diameter of drop rods such that the tensile stress within the rods does not exceed
6N/mm2 for fire ratings up to 240 minutes. (This may be increased to 10N/mm2 if only a
120 minutes fire rating is required).

9.5mm Durasteel boards fastened to lower flange of steel channels with M5.5 steel self-
drill and tap Tek screws at 200mm nominal centres. Fixings a minimum of 12mm from
edge of sheet and a maximum of 50mm from corners. Length of fixing to be sufficient to

ensure appropriate penetration of screw thread in accordance with screw
manufacturer's recommendations. Longitudinal board joints coincide with primary
channels, transverse board joints backed by steel channel the same size as the primary
channels. Longitudinal and transverse channel members are either welded together or
joined with steel angle cleats, minimum 60mm x 60mm x 3mm thick x 60mm long,
fastened to each channel member with two M10 steel bolts and nuts.

Where an expansion allowance is provided within the primary channels, steel jointing
channels, minimum 50mm flanges x 3mm thick, are fastened to the primary channels
with M10 steel bolts and nuts. The width of the jointing channel (web dimensions)
should be such that it is a close fit within the primary channels.

On one side of the expansion gap the primary and jointing channels are connected with
minimum two M10 bolts. On the opposite side the channels are connected, through
slotted holes, with minimum two M10 bolts fitted with fusible washers.

For fire attack from below, an expansion allowance of at least 6mm per metre is
required for primary channels longer than 4m.

For fire attack from above, an expansion allowance of at least 6mm per metre is
required for all sizes of ceiling. As drop rods support the ceiling, the length and width of
ceiling membrane is unrestricted.

Durasteel Suspended Ceiling Membrane E240 EI120 (fire from
below)
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• Fire resistance: 240 minutes integrity 120 minutes insulation (Fire attack from
below)
• Overall depth: 108.5mm

or M12 all steel expanding anchors (or equivalent for alternative types of supporting

hexagon full nuts.

6N/mm2 for fire ratings up to 240 minutes. (This may be increased to 10N/mm2 if only a
120 minutes fire rating is required).

9.5mm Durasteel fillet strips fitted over the upper and lower faces of the channel
members. Fillets must overlap the channels by at least 20mm on both sides.

9.5mm Durasteel boards fastened (through fillet strips) to lower flange of steel channels
with M5.5 steel self-drill and tap Tek screws at 200mm nominal centres. Fixings a
minimum of 12mm from edge of sheet and a maximum of 50mm from corners. Length
of fixing to be sufficient to ensure appropriate penetration of screw thread in
accordance with screw manufacturer's recommendations.

Longitudinal board joints coincide with primary channels, transverse board joints backed
by steel channel the same size as the primary channels.

Longitudinal and transverse channel members are either welded together or joined with
steel angle cleats, minimum 60mm x 60mm x 3mm thick x 60mm long, fastened to each
channel member with two M10 steel bolts and nuts.

Rock wool insulation 80mm x 140 kg/m3 nominal density, fitted over the soffit layer of
Durasteel by filling the channels. Joints in layers of rock wool overlap by at least 150mm.



As drop rods support the ceiling, the length and width of ceiling membrane is
unrestricted

Durasteel Suspended Ceiling Membrane EI120 (fire from above
or below)

• Fire resistance: 120 minutes integrity and insulation (Fire from above or below)
• Overall depth: 166mm


hexagon full nuts.

10N/mm2.

6 mm Durasteel boards fastened to lower flange of steel channels with M5.5 steel self-
manufacturer's recommendations. Longitudinal board joints coincide with primary
channels, transverse board joints backed by steel channel the same size as the primary
channels.


Rock wool insulation 80mm x 140 kg/m3 nominal density, laid over the steel channels.
Joints in layers of rock wool overlap by at least 150mm.




required for all sizes of ceiling.

unrestricted.

or below - method 1)

• Fire resistance: 240 minutes integrity & insulation. (Fire attack from above or
below)

or M12 allsteel expanding anchors (or equivalent for alternative types of supporting

hexagon full nuts.

6N/mm2 for fire ratings up to 240 minutes.

9.5mm Durasteel boards fastened to lower flange of steel channels with M5.5 steel self-
manufacturer's recommendations.

by steel channel the same size as the primary channels. Longitudinal and transverse
channel members are either welded together or joined with steel angle cleats, minimum
60mm x 60mm x 3mm thick x 60mm long, fastened to each channel member with two
M10 steel bolts and nuts.

Rock wool insulation, total of 120mm x 140 kg/m3 nominal density fitted with 2 x 60mm
thick layers, one layer fitted over the Durasteel soffit layer by filling the channels and
the second layer fitted over channels. Joints in layers of rock wool overlap by at least
150mm.

A layer of 1.5mm thick steel sheet is laid on top of the upper layer of rock wool. Where
an expansion allowance is provided within the primary channels, steel jointing channels,
minimum 50mm flanges x 3mm thick, are fastened to the primary channels with M10
steel bolts and nuts. The width of the jointing channel (web dimensions) should be such
that it is a close fit within the primary channels.

slotted holes, with minimum two M10 bolts fitted with fusible washers. For fire attack
from below, an expansion allowance of at least 6mm per metre is required for primary
channels longer than 4m.


unrestricted.

or below - method 2)

• Fire resistance: 240 minutes integrity & insulation. (Fire attack from above or
below)
• Channel (minimum): 60mm x 150mm x 60mm x 3mm


hexagon full nuts.

6N/mm2 for fire ratings up to 240 minutes.

9.5mm Durasteel fillet strips fitted over the upper and lower faces of the channel
members. Fillets must overlap the channels by at least 20mm on both sides.

9.5mm Durasteel boards fastened (through fillet strips) to upper and lower flange of
steel channels with M5.5 steel self-drill and tap Tek screws at 200mm nominal centres.
Fixings a minimum of 12mm from edge of sheet and a maximum of 50mm from corners.
Length of fixing to be sufficient to ensure appropriate penetration of screw thread in

by steel channel the same size as the primary channels.


Rock wool insulation 150mm x 140 kg/m3 nominal density, fitted over the soffit layer of
Durasteel by filling the channels. Joints in layers of rock wool overlap by at least 150mm.

slotted holes, with minimum two M10 bolts fitted with fusible washers. For fire attack
from below, an expansion allowance of at least 6mm per metre is required for primary
channels longer than 4m.


unrestricted.

Durasteel Composite Membrane Plenum Ceiling E240 EI60 (Fire
from Below)

Introduction

This Durasteel composite membrane plenum ceiling may be constructed as a
selfsupporting membrane for areas up 3m x 2m (maximum span 3m); or as a suspended
ceiling system with hangers coincident with the longitudinal framing channels at
1500mm centres.

Promat Promatect -250 panels, fitted to underside of the Durasteel ceiling, contribute to
the fire insulation performance of the system, and also provide a fair face to the ceiling.

Construction

Self Supporting Ceiling Option: Weight (nominal) 37kg/m2

The maximum area as a self supporting ceiling (supported on all four edges) is 3m x 2m.

Perimeter framing (1) of 80mm x 60mm x 3mm CRC is fastened to surrounding
construction with M10 or M12 all-steel expanding anchors (or equivalent for alternative
types of supporting construction), at 500mm maximum centres.

Supporting channels (2) in 80mm x 60mm x 3mm CRC at 1200mm maximum centres are
either welded to the perimeter framing or joined using 120 x 60 x 3mm angled cleats
fastened to each channel member with two M10 steel bolts and nuts. Transverse 80mm
x 60mm x 3mm CRC (3) are installed coincident with the Durasteel end of board joints.

9.5mm Durasteel (4) is fastened to the underside of the framing using 38mm TEK screws
fixed at 200mm centres.

MF5 ceiling sections (5) are installed perpendicular to the Durasteel framing at 625mm
centres, with MF6 (6) channel at the ceiling perimeter fastened to the walls. The MF5
grid system is fastened to the CRC framework through the Durasteel panels, and to the
underside of Durasteel ceiling using 38mm TEK screws at 400mm centres.

A 15mm Promatect -250 ceiling lining (7) is fastened to the MF grid system using 32mm
Drywall screws at 200mm centres. (Screws are to be inserted 15mm from the board
edge, and 40mm from the corner of the board).

Note: Promatect -250 boards are installed parallel to the Durasteel panels (and at right
angles to the MF5 ceiling sections), but with staggered joints in both directions between
layers.

100mm wide Promatect -250 cover strips (8) are fastened behind the transverse joints
between the MF5 sections of the Promatect -250 boards, using 32mm drywall screws at
nominal 250mm centres, with the screws at 25mm from edge of the board, and 50mm
from ends of the cover strips.

Suspended Ceiling Option: Weight (nominal): 37kg/m2

Perimeter framing of 80mm x 60mm x 3mm CRC (1) is fastened to surrounding
construction with M10 or M12 all-steel expanding anchors (or equivalent for alternative
types of supporting construction) at 500mm maximum centres.

Primary channels of 80mm x 60mm x 3mm CRC (2) at 1200mm maximum centres
fastened to the perimeter and suspended from the building structure above the ceiling
membrane using steel drop rods at maximum 1.5m centres. The threaded rods pass
through clearance holes in the upper fl ange of the channels, and are fastened with steel
hexagon full nuts.

The diameter of the hanger rods are such sized so that the tensile stress within the rods
does not exceed 6N/mm2.

An expansion allowance of at least 6mm per metre is required for primary channels
longer than 4m.

channels (minimum 50mm fl anges x 3mm thick) are fastened to the primary channels


Transverse 80mm x 60mm x 3mm CRC (3) are cleated between the primary channels,
coincident with the Durasteel board ends.

9.5mm Durasteel (4) is fastened to the underside of the framing using 38mm TEK screws
fixed at 200mm centres.

MF5 ceiling sections (5) are installed perpendicular to the Durasteel framing at 625mm
centres, with MF6 (6) channel at the ceiling perimeter fastened to the walls. The MF5
grid system is fastened to the CRC framework through the Durasteel panels, and to the
underside of Durasteel ceiling using 38mm TEK screws at 400mm centres.

A 15mm Promatect -250 ceiling lining (7) is fastened to the MF grid system using 32mm
Drywall screws at 200mm centres. (Screws are to be inserted 15mm from the board
edge, and 40mm from the corner of the board).

Note: Promatect -250 boards are installed parallel to the Durasteel panels (and at right
angles to the MF5 ceiling sections), but with staggered joints in both directions between
layers. 100mm wide Promatect -250 cover strips (8) are fastened behind the transverse
joints between the MF5 sections of the Promatect -250 boards, using 32mm drywall
screws at nominal 250mm centres, with the screws at 25mm from edge of the board,
and 50mm from ends of the cover strips. Since drop-rods support the ceiling, the length
and width of ceiling membrane is unrestricted.

Durasteel DD120 and DD240 Fire Shutters

Leaf

• Overall Thickness: 12mm (DD120) 28mm (DD240)
• Material: 9.5mm thick Durasteel sheet
• Jointing Construction: Mitred and Welded

Frame

• Overall Frame Depth: 80mm
• Material: 45 x 80 x 45 x 6mm thick Z-section/25 x 15 x 3mm thick angle section
• Jointing: Mitred and Welded joints
• Type and Configuration: 3-sided frame with trailing edge flame trap

Finish

• Frame and Leaf: Standard shop applied zinc based primer, ready for site painting
(P3)

Ironmongery

• Standard weight counterbalance system, heavy duty mild steel track

Certification

• BS 476: Part 22: 1987

Dimensional Details Ref Single Leaf Doorset Example Calculation
Structural opening width A A 920mm
Structural opening height B B 900mm
Overall frame width C (A + 92 = C) 1012mm

Overall frame length D (B + 96 = D) 996mm
Door leaf width E ((B + D + 92 = E) 1988mm
Door leaf height F (A + 178 = F) 1098mm

Durasteel Fire Barrier E240 Integrity Only

• Fire resistance: 240 minutes integrity only (Fire attack from either face)
(Formerly referred to as the STI 240 system)
• Channel (minimum): 80mm x 60mm x 3mm (for heights up to 6m)
• Overall width: 89.5mm
• Estimated sound reduction: 33dB

Perimeter channels fastened to surrounding construction with M10 or M12 all-steel
expanding anchors (or equivalent for alternative types of supporting construction) at
500mm maximum centres.

The vertical channels are set at a maximum 1200mm centres. Horizontal and vertical
channel members either welded together or joined with steel angle cleats, minimum

A single layer of 9.5mm Durasteel fixed on one side of channel with M5.5 steel self drill
and tap Tek screws at 250mm nominal centres. Fixings a minimum of 12mm from edge
of sheet and a maximum of 50mm from corners. Length of fixing to be sufficient to
manufacturer's recommendations.

Vertical board joints coincide with studs, horizontal board joints are backed by steel
channel the same size as the vertical studs.

Expansion allowance will be required for barriers above 4 metres high. Please contact us
for further information.

Steel channel sizes for barrier heights up to 15 metres
Height of Barrier (m) Channel size (mm x mm x mm) Estimated Sound Insulation Rw (dB)
0-6 80 x 60 x 3 33
6-9 150 x 60 x 3 33
9 - 12 Two 150 x 60 x 3 Back to back 33
12 - 15 Two 175 x 60 x 3 back to back 33

Back to back channels fastened together with M10 steel bolts and nuts at 500mm
maximum centres. The vertical joints in the Durasteel should be offset by 30mm from
the centreline of the back-to-back studs, to avoid a straight through path for hot gases.
Horizontal channels are single channels.

Durasteel Fire Barrier E240 EI60

• Fire resistance: 240 minutes integrity - 60 minutes insulation (Fire attack from
either face)
(Formally referred to as the STI 240/60 System)
• Overall width: 118mm




9.5mm Durasteel fillet fixed on both sides of channel. Fillet strips to overlap channel by
minimum of 20mm on both sides.

9.5mm Durasteel sheets fixed through fillet on both sides of the channel with M5.5 steel
self drill and tap Tek screws at 250mm nominal centres.

Fixings a minimum of 12mm from edge of sheet and a maximum of 50mm from corners.
Length of fixing to be sufficient to ensure appropriate penetration of screw thread in

Vertical board joints coincide with studs, horizontal board joints are backed by steel
channel the same size as the vertical studs. Expansion allowance will be required for
barriers above 4 metres high.

Steel Channel sizes for barrier heights up to 15 metres
Height of Channel size (mm x Durasteel fillets Rock Wool Estimated sound
Barrier mm x mm) per face infill Insulation Row
0-6 80 x 60 x 3 1 None 42
6-9 150 x 60 x 3 1 None 42
Two 150 x 60 x 3
9 - 12 1 None 42
Back to back
Two 200 x 60 x 3
12 - 15 1 None 42
back to back


Durasteel Fire Barrier E240 EI120

either face)



9.5mm Durasteel fillet strips fixed on both sides of channel, number of fillet strips
according to requirements in Table below. Fillet strips to overlap channel by minimum
of 20mm on both sides. 9.5mm Durasteel sheets fixed through the fillet on both sides of
channel, with M5.5 steel self drill and tap Tek screws at 250mm nominal centres. Fixings
a minimum of 12mm from edge of sheet and a maximum of 50mm from corners. The
length of fixing to be sufficient to ensure appropriate penetration of screw thread, in
accordance with manufacturer's recommendations. Vertical board joints coincide with
studs, horizontal board joints are backed by steel channel the same size as the vertical
studs. Rock wool infill, according to the table below, is fitted into the channels. The
layers are staggered by a minimum of 150mm.

If the rock wool does not fill the cavity, it must be fastened into position with 2.5mm-
diameter steel stud-welded pins and 38mm-diameter spring steel washers. The pins are
positioned in a grid 400mm x 400mm maximum. Expansion allowance will be required
for barriers above 4 metres high.

Height of Channel size (mm x Durasteel fillets Estimated sound
Rock Wool infill
Barrier mm x mm) per face Insulation Row
2 x 40mm x
0-6 80 x 60 x 3 1 47
140kg/m3
3 x 50mm x
6-9 150 x 60 x 3 None 51
80kg/m3
Two 150 x 60 x 3 3 x 50mm x
9 - 12 None 53
back to back 80kg/m3
Two 200 x 60 x 3 4 x 50mm x
12 - 15 None 53


Durasteel Fire Barrier EI240

either face)
• Channel (minimum): 80 x 60 x 3 (for heights up to 6m)



9.5mm Durasteel fillets fixed on both sides of channel, number of fillet strips according
to requirements in Table below. Fillet strips to overlap channel by minimum of 20mm on
both sides.

9.5mm Durasteel sheets fixed through the fillet on both sides of channel, using M5.5
steel self drill and tap Tek screws at 250mm nominal centres. Fixings a minimum of
12mm from edge of sheet and a maximum of 50mm from corners. The length of fixing
to be sufficient to ensure appropriate penetration of screw thread, in accordance with
manufacturer's recommendations. Vertical board joints coincide with studs, horizontal
board joints are backed by steel channel the same size as the vertical studs.

Rockwool infill, according to the table below, is fitted into the channels. The layers are
staggered by a minimum of 150mm. If the rock wool does not fill the cavity, it must be
fastened into position with 2.5mm-diameter steel stud-welded pins and 38mm-
diameter spring steel washers. The pins are positioned in a grid 400mm x 400mm
maximum. Expansion allowance will be required or barriers above 4 metres high.

Height of Channel size (mm x Durasteel fillets Estimated sound
Rock Wool infill
Barrier mm x mm) per face Insulation Row
3 x 40mm x
0-6 80 x 60 x 3 2 50
140kg/m3
3 x 50mm x
6-9 150 x 60 x 3 2 55
100kg/m3
Two 150 x 60 x 3 3 x 50mm x
9 - 12 2 55
Two 200 x 60 x 3 4 x 50mm x
12 - 15 1 56


Typical Connection Details

Please note that the following Durasteel system connection details are examples only.
Connection details for each system will differ according to the specific requirements of
the system.

Wall Interface

1. 150mm x 60mm x 3mm CRC Frame
2. M10 Expanding Bolts at 500mm Maximum Centres
3. 15mm Promatect 250
4. 9.5mm Durasteel Sheet
5. Tek Screws at 200mm Maximum Centres
6. Silicone to all Abutments

Sheet Join Interface

1. 150mm x 60mm x 3mm CRC Frame Back To Back
2. M10 x 25mm Bolts c/w Nut and Washer

Building Steel Penetration Interface

3. 9.5mm Durasteel Sheet (2nd layer)
4. Existing Steelwork with Minimum 12mm Sealant Around Steelwork


Pipe Penetration Interface

5. Existing Pipe
6. Rockwool Insulation
7. Promaseal Fire Compound
8. 100mm x 50mm x 3mm Rolled Steel Angle

Cleating - Corner Interface Elevation View

3. M10 x 25mm Hex HD Bolts or M10 x 20mm CSK HD Bolts c/w Nut and Washer
4. 120mm x 60mm x 3mm Angle Cleats
5. M10 x 20mm CSK HD Bolts c/w Nut and Washer

Cleating - Perimeter Interface Elevation View

4. 2 No. 120mm x 60mm x 3mm Angle Cleats

Cleating - Section View


4. 2 No. 120mm x 60mm x 3mm Angle Cleats

Cleating - Internal Interface Elevation View

3. 120mm x 60mm x 3mm Angle Cleat

Cleating - Internal Interface Section View

3. 120mm x 60mm x 3mm Angle Cleat

Suspended Movement Head Detail

1. Profile Cut and Seal to Purlins
2. Curved 150mm x 60mm x 3mm CRC Head Channel
7. Slotted Cleat for 80mm x 60mm x 3mm CRC Frame

Standard Movement Head Detail

1. Profile Cut and Seal to Purlins
2. Curved 200mm x 60mm x 3mm CRC Head Channel
7. Slotted Cleat for 150mm x 60mm x 3mm CRC Frame

Wall Fixing

1. Dwarf Wall
2. Existing Plasterboard Wall
3. Mastic
4. Mastic

Roller Shutter Steelwork Fixing

1. 50mm x 50mm x 3mm Angle
7. Welded Plate Between Flanges
8. Mastic

Durasteel projects ref..

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