FIRE SEPARATING COMPONENTS

IN CLASS 2 AND 3 BUILDINGS

COMMON DEFECTS ASSOCIATED WITH

BUILDING CLASSIFICATION
The Building Code of Australia (BCA) classifies buildings based upon their intended end use. A Class 2 building is: a building containing 2 or more sole-occupancy units each being a separate dwelling. Class 2 buildings may share both horizontal and vertical separating components, such as floors and ceilings. A Class 3 building is: a residential building, other than a building of Class 1 or 2, which is a common place of long term or transient living for a number of unrelated persons. Examples of Class 3 buildings include:
a boarding-house, guest house, hostel, lodging-house or backpackers accommodation a residential part of a hotel or motel a residential part of a school accommodation for the aged, children or people with disabilities a residential part of a health-care building which accommodates members of staff a residential part of a detention centre.

This information brochure relates to Class 2 and 3 buildings only.

PASSIvE FIrE PrOTECTION SySTEMS

A fire safety system is one method or a combination of methods used in a building to: warn people of an emergency provide for safe evacuation restrict the spread of fire extinguish a fire. Fire safety systems include both active and passive systems or a combination of both. An example of an active system is a fire alarm while a passive system may be the construction of a fire rated wall or fire rated column. This information brochure concentrates on passive fire protection systems including: external walls; fire separating walls; floor and ceiling systems; and commonly occurring defects BSA sees in passive fire protection systems.

Common wall between Class 1 and Class 2 buildings

Class 2 dwelling Class 1 single dwelling (may be one or more storeys) Class 2 dwelling

Class 2 building containing two or more separate dwellings located one above the other

Elevation

ExTErNAL WALLS
Defective external wall protection is generally caused by common misunderstandings including: Openings constructed in fire walls in contravention of the requirements of Section C3.2 of the BCA.
Section C3.2 of the BCA states that no openings whatsoever are permissible in an external wall that is required to have a Fire Resistance Level (FRL) and where the wall is within: (i) 1 metre of a fire source feature (the far boundary of a road adjoining the allotment, a side or rear boundary of the allotment, or an external wall of another building on the allotment which is not a shed, private garage or carport) in a building of no more than one storey; or (ii) 1.5 metres of a fire source feature in a building of more than one storey. Inadequate protection of openings within the specified distance of fire source features, including exposed openings on walls that run at any angle to the boundary or fire source feature. If a wall containing openings is situated more than the minimum distances from a fire source feature, but less than the distances outlined below, then the openings in the wall must be provided with fire protection. (i) 3 metres from a side or rear boundary of an allotment; or (ii) 6 metres from the far boundary of a road adjoining the allotment, if not located in a storey at or near ground level; or (iii) 6 metres from another building on the allotment that is not Class 10

closing doors or -/60/30 self closing or automatic closing fire doors. (ii) For windows Either external wall wetting sprinklers used with windows that are automatically or permanently fixed in a closed position or -/60/- fire windows or -/60/automatic fire shutters. (iii) For openings other than doors or windows Either external wall wetting sprinklers or construction having an FRL of not less than -/60/-.

The total area of openings requiring protection must not exceed more than one third of the area of the external wall of the storey. Exposed windows or other openings that are within the prescribed distances from the boundary (as mentioned above) and occur on a wall running perpendicular or at any other angle to the boundary or fire source feature must also be appropriately protected and achieve the required FRL. This is a requirement that is frequently overlooked when buildings are being designed, constructed and certified.

road

less than 6m

building side boundary less than 6m

building

less than 3m side boundary

The type of protection required includes:

(i) For doorways Either external wall wetting sprinklers used with self closing or automatic

less than 3m rear boundary

FIrE SEPArATING WALLS

Some common defects observed in fire separating wall construction include: Unprotected services passing through the wall

Perimeter and intermediate nailing spaces of plasterboard not consistent with the manufacturers specifications

Fire walls not being built to correct sizes, leaving excessive gaps over and around walls

Inadequate setting of plasterboard joints and over nail heads

Inadequate protection of: the joint between the top of the wall and the underside of roof sheeting; and metal battens crossing a fire separating wall that have not been filled with fire resistant material

Plasterboard should be set with a plasterbased bonding coat and paper tape covering the joints. All nail and screw indentations should be filled. Complying with the BCA and following the manufacturers recommendations to the full are essential to achieve the Fire Resistance Level of the tested wall system. valley boards crossing a fire separating wall

The insulation should be installed in the metal batten directly above the block wall - creating a complete vertical barrier.

FIrE SEPArATING FLOOrS AND CEILINGS

Under the BCA Class 2 and 3 buildings must be constructed with various FRLs, depending upon the height of the building being constructed. Floors are commonly constructed from cast in situ concrete, or pre-cast or pre-stressed concrete panels with suitable topping screeds, but they may also be timber framed and lined on the underside with fire rated plasterboard or a similar product. Defects in these fire separating floors are not common, but the fire stopping or protection of penetrations is often poorly constructed. The methods of treating penetrations and some of the associated problems will be discussed later in this information booklet. Class 2 and 3 buildings of Type B or C construction are required to be constructed to achieve: a floor/ceiling system that incorporates a ceiling which has a resistance to the spread of fire to the space above of at least 60 minutes; or an FRL of not less than 30/30/30; or they must be constructed to have a fire protective covering on the underside of the floor, incorporating beams, if the floor is combustible or of metal. Internal walls that are required to have an FRL must extend to the underside of fire resistant ceiling system or the fire resistant underside of the floor above. Internal walls on the top floor must extend to the underside of the roof covering if it is non-combustible (except for roof battens of 75mm x 50mm or less and sarking), or 450mm above the roof if the roof covering is combustible. Many manufacturers produce fire resistant ceiling systems which they have had tested and accredited. These ceilings must be

installed strictly in accordance with these tested systems. BSA has noted the effect of the ceilings is severely compromised by some poor installation practices and excessive penetrations. Most manufacturers will allow ceilings to be penetrated, provided the penetrations are installed with proprietary tested systems. BSA often finds penetrations that have not been installed in accordance with the tested data, and even penetrations that have no fire resistance whatsoever!

Other common construction defects include: sheeting systems fixed to non-tested and non-resistant ceiling suspension systems; screw fixings being inconsistent with the manufacturers tested systems; and inadequate or inappropriate sealing at the wall to ceiling junctions.

PENETrATIONS THrOUGH FIrE SEPArATING WALL AND FLOOr SySTEMS

To ensure that the overall FRL of the wall has not been compromised, any penetration through fire separating wall and floor systems must be installed strictly in accordance with the tested system. There are a number of proprietary systems such as fire collars, fire pillows, fire shutters, fire dampers, fire doors, and fire rated sealants which are commonly used for treating penetrations through fire resisting elements. BSA has found that these systems are very often incorrectly installed, which significantly compromises the FRL of the wall or floor.

No screws? No problem - use silicone.

Fire Collars
In order to maintain the required FRL of the wall and floor, fire collars must be installed in accordance with the tested data. Certifiers should be checking to ensure the installation of collars is consistent with the tested data prior to certifying the constructions. It is important that the holes for fixing the collar to the slab are positioned in such a way that suspended pipework and other obstructions dont impede access to drill the holes for fixing the collar. Fire collar systems are deisgned to perform in a very specific way. Failure to install the collar in exactly the same manner as the tested prototype will not result in a deemed to satisfy installation and may compromise the FRL of the wall or floor. One of the most common defects BSA identifies with the installation of fire collars is the use of inappropriate fixings or fixing methods. For example, malleable fixings that will melt at low temperatures significantly compromise the integrity of the fire resisting wall or floor and must not be used.
Alternative fixing method!

Another issue sometimes encountered when installing fire collars is that the holes in the flange of the collar line up with cast in reinforcing steel and prevent holes from being drilled in these locations. Although some collars meet necessary FRL requirements with one fixing missing it is usually better to drill another hole through the flange and into the concrete to facilitate the installation of the final fixing. Remember though, any departure from the tested system must be checked with the manufacturer and certified by the certifier.

The following examples are almost unbelievable and demonstrates either a total lack of understanding of how fire collars work or lazy and negligent installation practices. You also have to wonder about the certifier who passed these constructions!

Fire Pillows
Fire pillows are typically used to protect penetrations through fire separating walls and floors that are an irregular size and shape and therefore difficult to protect. The most common defect associated with fire pillows generally relates to pillows being inadequately compressed into the opening they are protecting.

Fire Shutters
Fire shutters in Class 2 and 3 buildings are not common, but they are occasionally used to protect windows in external walls. The shutters are triggered by either activation of a fusible link or by motorised closing devices activated by the early warning evacuation system. The most common defect observed with these installations is excessive clearances between the frame and the fire resisting wall. It is important to ensure that the particular fire shutter being used is compatible with and has been tested in the type of wall into which it is proposed to be installed.

Fire Dampers
Intumescent fire dampers generally consist of parallel slats incorporating intumescent material in a metal frame. They are generally used to provide fire containment through ducting. When subjected to heat the intumescent slats swell to form a rigid barrier against the passage of flames and hot gases. It is important that dampers are installed strictly in accordance with the manufacturers specifications and that the damper is suitable for the location in which it is being used and is of the correct FRL.

Fire Doors
The FRL of fire doors applies to the overall installed door assembly or system, not the individual components of the door. Fire door systems typically include the door, frame, lock, hardware, seals, any packing and fixing to the wall, and the wall the door is built into. Different fire doors are suitable for and have been tested in different wall materials such as concrete, masonry (including lightweight blocks), plasterboard and other proprietary wall types. Some common defects in the installation of fire doors and their frames include issues such as: operational forces being either inadequate or too forceful doors not self-closing or self-latching doors being altered from the tested system door seals being inappropriate or functioning inappropriately; and in some cases fire doors being fitted with inappropriate door furniture such as deadbolts. The most common defect, however, is the attainment of allowable clearances around the door. Perimeter clearances must not exceed the allowed 3mm and the clearance at the base of hinged doors must not exceed 10mm. Although there are some similarities between the properties of different fire doors, they are a proprietary product and the fire test data and field application of each type is different. Most fire door manufacturers provide user manuals which detail installation procedures and provide information of the door hardware that has been tested and approved for each door. It is essential these instructions are strictly followed, to ensure the required FRL of the wall and door is achieved. On completion of all fire door assemblies fire doors must be inspected, certified and tagged with their respective FRL.

Something often overlooked with fire door systems is the requirement to ensure the operation of the doors and door hardware is regularly inspected and tested. If any components are inadequately functioning, adjustment and lubrication or replacement of moving parts should occur immediately. Although maintenance of fire door systems is often out of the builder or contractors control, the builder and contactor still have a duty of care to ensure that maintenance and inspection requirements are documented and given to the building owner on completion.

Striker plates cut into fire door frame

Fire Stopping and Sealants

Fire proofing openings for services, particularly smaller penetrations like one or more electrical cables, poses a particular problem for builders and contractors because the penetration is often an irregular shape. Numerous fire stopping products are readily available from hardware retailers and specialist fire stopping manufacturers. It is essential that builders, contractors and certifiers obtain the test data and manufacturers installation procedures prior to selecting stopping or sealant for a particular application. Fire resistant sealants or caulks often incorporate intumescent additives which swell up and provide an effective fire stopping barrier. BSA has identified numerous defects caused by the inadequate sealing of penetrations or by the contractor using sealants and stopping not suitable for the purpose. For example, it is not a compliant system if a penetration is sealed with a particular product that is larger than the penetration used in the tested system. As a general rule, fire stopping will comply if it is used in a penetration smaller than the tested system, but not in penetrations larger than the tested system. BSA sees many openings which have no stopping or sealing because it has been overlooked by both the contractor and the builder and the breach has not been identified by the certifier.

Untested methods!

No stopping or sealing

Another important consideration when looking at the compliance of fire stopping systems is the number and proximity of service penetrations within the opening and the type of configuration of any support for the services, such as cable trays. Some of the areas of concern include: A lack of coordination and cooperation between the designer, builder and certifier of fire separating components. Fire separating components not constructed in accordance with tested data. Fire separating components not constructed in accordance with tested systems and not appropriately assessed as alternative solutions.

?
3

Unbelievably, this was their rectification attempt!

Who knows what BSAs building inspectors will discover when they next inspect the site?

A random BSA audit discovered several fire rated shafts coming through a rated ceiling that had been signed off. The contractor was requested to rectify the defect.

www.bsa.qld.gov.au

1300 272 272

www.beconstructive.com.au

1800 798 488