Wheatstone Project

LNG Plant
Specification for Proprietary Cementitious
Fireproofing

0 13-Jan-2010 Issued for Feed JSY BSF WV

A 12-Oct-2009 Issued for Review JSY BSF WV

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IP Security Public Total number of Pages (including Cover sheet): 10

Contractor
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DOCUMENT
CONTROL NO. WS1 0000 FGS SPC BEC 000 00102-000 0

© Chevron Australia Pty Ltd

 Wheatstone Project LNG Plant Document No: WS1-0000-FGS-SPC-BEC-000-00102-000
Specification for Proprietary Cementitious Fireproofing Revision: 0
Revision Date: 13-Jan-2010

Wheatstone Project LNG Plant

Specification For Proprietary

Cementitious Fireproofing

Bechtel Confidential
© Bechtel Oil, Gas and Chemicals, Inc. 2010. All rights reserved.
This document contains information that is confidential and proprietary to Bechtel Oil,
Gas and Chemicals, Inc.

00B 13-Jan-2010 Issued for Feed JSY BSF WV

00A 12-Oct-2009 Issued for Review JSY BSF WV
Rev. Date Revision Description By Check Appr
BECHTEL OG&C CHEVRON DOCUMENT NO. REV.
WS1-0000-FGS-SPC-BEC-000-00102-000 0
BECHTEL DOCUMENT NO. REV.
25504-100-3PS-NF00-F0002 00B

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Refer to electronic documents in the EDMS for current versions.
 Wheatstone Project LNG Plant Document No: WS1-0000-FGS-SPC-BEC-000-00102-000
Specification for Proprietary Cementitious Fireproofing Revision: 0
Revision Date: 13-Jan-2010

TABLE OF CONTENTS

1.0 SCOPE ......................................................................................................... 4

2.0 QUALITY STANDARDS............................................................................... 4

3.0 SUBMITTALS............................................................................................... 5

4.0 MATERIALS ................................................................................................. 6

5.0 MOCK-UP..................................................................................................... 7

6.0 INSTALLATION OF FIREPROOFING ......................................................... 8

7.0 EXTERNAL TOPCOAT ................................................................................ 9

8.0 INSPECTION AND TESTING....................................................................... 9

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Bechtel Confidential. © 2010 Bechtel Oil, Gas and Chemicals, Inc. All rights reserved.
Electronic documents, once printed, are uncontrolled and may become outdated.
Refer to electronic documents in the EDMS for current versions.
25504-100-3PS-NF00-F0002-00B
 Wheatstone Project LNG Plant Document No: WS1-0000-FGS-SPC-BEC-000-00102-000
Specification for Proprietary Cementitious Fireproofing Revision: 0
Revision Date: 13-Jan-2010

1.0 SCOPE

1.1 General

This specification provides the requirements for installation of fireproofing materials for
structural steel and vessel/equipment supports. Proprietary cementitious fireproofing,
Carboline Pyrocrete 241, at a thickness of 32mm (1 ¼ inch) required to be acceptable for an
LNG fire incident shall be applied to the surfaces. An LNG fire test shall be a 3 barg over
pressure explosion test followed by a J-30 jet fire test. Unless indicated otherwise, caulking
of joints and external top coating of the fireproofing shall be included.

1.2 Extent of Fireproofing

The materials requisition or contract attachments indicate the extent of fireproofing.

Fireproofing heights and construction block-outs are indicated on structural steel drawings.
Equipment skirts and saddles requiring fireproofing are indicated on equipment drawings or
equipment lists. Controls/instrumentation fireproofing is excluded from the scope of this
specification.

1.3 Safety and Environmental

1.3.1 All surface preparation, materials, and coatings work shall comply with all applicable
environmental and safety provisions, laws, regulations, ordinances, etc., of the city, county,
state, province, in NW Australia pertaining to the work being performed and the coating
materials being used.

1.3.2 Seller shall comply fully with OSHA Hazard Communication Standard 29 CFR 1910.1200
and 19CFR 1926.59 or the applicable country code. Material Safety Data Sheets (MSDS’s)
shall be available for review at the jobsite.

1.3.3 The volatile organic compound (VOC) content of all materials shall meet Federal, State, and
Local or other Regulatory requirements.

2.0 QUALITY STANDARDS

2.1 General

2.1.1 The Seller shall control the quality of items and services to assure that completed
fireproofing work conforms to the requirements of this specification and the applicable
codes and standards. The quality program shall provide for assurance that only accepted
fireproofing materials are used, that inspection of the surface preparation and the
fireproofing application is implemented for all phases of work performed, and that
documentation is prepared and maintained to furnish evidence of compliance with this
Standard Specification and accepted procedures. The application subcontractor shall be
approved by the material supplier prior to beginning work.

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Electronic documents, once printed, are uncontrolled and may become outdated.
Refer to electronic documents in the EDMS for current versions.
25504-100-3PS-NF00-F0002-00B
 Wheatstone Project LNG Plant Document No: WS1-0000-FGS-SPC-BEC-000-00102-000
Specification for Proprietary Cementitious Fireproofing Revision: 0
Revision Date: 13-Jan-2010

2.1.2 The Seller, including any lower-tier organizations engaged by him, shall be subject to
surveillance inspection and audit by the Buyer's inspector for compliance with the
requirements of this specification. This surveillance inspection and audit does not relieve
the Seller from the responsibility for conformance to the requirements set forth in the
procurement documents.

2.1.3 The Buyer's inspector shall be provided with a detailed schedule and shall be notified of all
required hold and witness points requiring inspection by the Buyer prior to the scheduled
date for fireproofing. Failure to provide the required notification shall result in the
requirement for reinspection or rework.

2.1.4 The Seller's inspector shall identify and document all uncorrected deviations from the
specification, codes and standards and shall transmit these deviations to the Buyer for
review and disposition.

2.1.5 The nozzlemen shall be qualified to ACI Guide 506.3. Qualification testing shall be subject
to inspection, review and acceptance by the Buyer.

2.2 Codes and Standards

The latest revisions of the following specifications are applicable to the extent specified:

ACI 506.3 Guide to Certification of Shotcrete Nozzlemen

ASTM C 309 Specification for Liquid Membrane-Forming Compounds for Curing

Concrete

ASTM D 790 Test Method for Flexural Properties of Unreinforced and Reinforced
Plastics and Electrical Insulating Materials

ASTM E 605 Test Methods for Thickness and Density of Sprayed Fire Resistive
Material Applied to Structural Members

ASTM E 2240 Durometer Test for Indentation Hardness of Homogeneous Materials

AWS D1.1 Structural Welding Code - Steel

WS1-0000-CRR-SPC-BEC-000-00101-00 25504-100-3PS-NX00-F0001
Specification for Protective Coatings

3.0 SUBMITTALS

3.1 The Seller shall submit a listing of all materials to be used in shop and field fireproofing
including field repair of blockouts. Seller shall submit detailed sketches showing location of
reinforcement and cross section of typical fireproofed steel shapes and equipment supports.

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Electronic documents, once printed, are uncontrolled and may become outdated.
Refer to electronic documents in the EDMS for current versions.
25504-100-3PS-NF00-F0002-00B
 Wheatstone Project LNG Plant Document No: WS1-0000-FGS-SPC-BEC-000-00102-000
Specification for Proprietary Cementitious Fireproofing Revision: 0
Revision Date: 13-Jan-2010

3.2 The Seller's written procedures for storage, shipping, handling, topcoating, surface
preparation, environmental control, application, touch up and repair, curing, and inspection
of the fireproofing system shall be submitted for Buyer’s review and permission to proceed
prior to use. For shop applied fireproofing, blockouts, handling and shipping procedures, as
well as the schedule must be covered in detail. Conflicts, if any, between Seller's
recommendations and this Specification shall be noted; however, this specification shall
prevail.

3.3 The Seller's proposed fireproofing verification forms for daily inspection records shall be
submitted for Buyer’s review and permission to proceed prior to use.

3.4 A detailed fireproofing verification report, in accepted form, shall be completed each day
during the work and shall be submitted for record. The final verification report shall include
the values from testing obtained in accordance with this specification and a statement of
conformance verifying that the required materials were used and that the accepted
application procedures and specifications were followed. The responsible inspector must
approve and sign these reports on a daily basis.

3.5 The seller shall furnish manufacturer's test certificates indicating that the fireproofing
material conforms to printed data sheet values for the following laboratory tests:

• Flexural strength per ASTM D 790.

• Surface hardness per ASTM E 2240.

3.6 A detailed welding procedure shall be submitted for Buyer’s review and permission to
proceed prior to use if the required reinforcement anchors were not attached by the
structural steel or equipment fabricator and must be attached by welding by the Seller.

4.0 MATERIALS

4.1 Proprietary Cementitious Fireproofing

The material shall be the following at the specified thickness:

Carboline Pyrocrete 241 - 32 mm (1.25 inches) minimum thickness,.

Alternate materials shall not be acceptable. System design shall be warranted against
cracking for a period of one year from initiation of plant operation, and design basis is 20
year minimum service life.

Fireproofing materials shall be durable, weather resistant, corrosion resistant, and

unaffected by chemicals typical of LNG processing plant environments. These materials
shall also be UV resistant.

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Bechtel Confidential. © 2010 Bechtel Oil, Gas and Chemicals, Inc. All rights reserved.
Electronic documents, once printed, are uncontrolled and may become outdated.
Refer to electronic documents in the EDMS for current versions.
25504-100-3PS-NF00-F0002-00B
 Wheatstone Project LNG Plant Document No: WS1-0000-FGS-SPC-BEC-000-00102-000
Specification for Proprietary Cementitious Fireproofing Revision: 0
Revision Date: 13-Jan-2010

4.2 Reinforcement

4.2.1 Reinforcement shall be in accordance with the fireproofing material manufacturer’s

instructions for the LNG acceptance testing. Tie wire and hog rings shall be used every
150mm along reinforcement joints to keep overlapping sheets of lath flush together.

4.2.2 For large flat surfaces such as skirts, Nelson studs (of a suitable height for the rating and
thickness) shall be spaced on 300 mm (12 inch) centers in both directions. All welding to be
done per Seller’s written procedure and AWS D1.1. Where studs, clips, etc., must be
welded to coated surfaces, touch-up paint the weld area and attachment.

4.2.3 For steel shapes only, anchors must be pneumatically driven pins such as Hilti EDN or ENK
types placed by the Seller.

4.2.4 Use 18 gage soft annealed tie wire and hog rings to lace reinforcing panels together.

4.2.5 Reinforcing lath shall be 1.85 kg/square meter (3.4 lbs/square yard), galvanized metal.

4.2.6 Hexagonal mesh shall be 50 mm (2 inches) by 18 gauge, galvanized and PVC coated.

4.3 Caulking

Any joints between fireproofing and steel where water may enter shall be caulked with Dow
Corning 795, Carboline Acrilast 570, or approved equal. Exposed edges shall be sealed
with caulk, mastic, or flashing to prevent seepage of water behind the fireproofing.

4.4 External Coating

External coating materials shall be a clear epoxy sealer or other coating as specified in the
referenced coating specifications. Deviations must be approved by the Buyer.

5.0 MOCK-UP

A sample 1 meter (3 foot) long column shall be fireproofed by each nozzleman qualified for
the work. The sample shall be inspected and tested in accordance with Section 8.0. Upon
acceptance of all physical properties, the finish shall be subject to inspection by the Buyer
and, if accepted, serve as a comparator to judge the trowel finish on the work. The finish of
the work for all surfaces shall be at least as smooth as the surfaces on one of the accepted
mock- ups.

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Electronic documents, once printed, are uncontrolled and may become outdated.
Refer to electronic documents in the EDMS for current versions.
25504-100-3PS-NF00-F0002-00B
 Wheatstone Project LNG Plant Document No: WS1-0000-FGS-SPC-BEC-000-00102-000
Specification for Proprietary Cementitious Fireproofing Revision: 0
Revision Date: 13-Jan-2010

6.0 INSTALLATION OF FIREPROOFING

6.1 Anchors shall be touched-up as specified in either the engineering coating specifications.
All surfaces must be cleaned free from oil or grease. Glossy surfaces, loose or flaking
paint, or similar surface conditions which would affect adhesion, must be corrected before
being covered.

6.2 For all structural members with field installed fireproofing, and a web depth of 305 mm (12")
or less, the fireproofing shall be a "boxed in" configuration. For all structural members with
a web depth greater than 305 mm, and all shop installed fireproofing, the fireproofing shall
be a contoured configuration. The applications shall conform to the LNG design based on
acceptance testing. For horizontal members where the top surface is not fireproofed, the
fireproofing shall extend completely over the bottom surface of the top flange and extend full
thickness outward and around the flange edge. The top surface of fireproofing shall be
sloped to allow for drainage.

6.3 For shop application before erection, blockout of the fireproofing for the field connections
are required. Shop applied reinforcement mesh shall extend at least 57.2 mm (2.25 inches)
into the area where the fireproofing material is blocked out to facilitate tie-in of site applied
mesh and site fireproofing.

6.4 Flat surfaces such as walls, ceilings, decks, and column web areas over 305 mm (12
inches) deep require the use of reinforcing mesh anchored on 305 mm centers.

6.5 Fireproofing shall be applied between 12.7°C (55°F) and 37.7°C (100°F) ambient
temperature with maximum relative humidity of 95%. Unless specified otherwise in the
purchase order, curing shall be accomplished by continuous dampening the fireproofing or
use of an ASTM C 309 coating/curing membrane.

6.6 Two application methods are approved: formed or shotcrete applied. All fireproofing not
placed in forms shall be finished smooth using the use of a wood float or trowel. The final
appearance shall be smooth, even, and aesthetically pleasing. The finish shall be as good
as or better than the work sample prepared and accepted by the Buyer as outlined in
Section 5.0. Light sanding or troweling of uncured surfaces may be required to obtain an
acceptable corner for caulking or surface appearance. Application by shotcrete method with
a trowel finish is acceptable utilizing qualified, experienced nozzlemen.

6.7 For field application, surrounding finished surfaces, such as painted walls, floors, exposed
ceilings, tile, windows, and in place equipment shall be protected from damage, drips,
spatter and overspray. Metal switch boxes, junction boxes, conduits, sprinkler heads,
aluminum window, and similar units shall be masked to protect from overspray of wet
material.

6.8 Any overspray or waste shall be removed while still wet and before setting. Clean-up may
be done with scrapers, soapy water, rags, etc. If fireproofing material is allowed to cure
before clean-up, it must be chipped or abraded away. Surrounding surfaces shall be
restored to the original condition at Seller's expense.
© Chevron Australia Pty Ltd Security Level 2 Page 8
Bechtel Confidential. © 2010 Bechtel Oil, Gas and Chemicals, Inc. All rights reserved.
Electronic documents, once printed, are uncontrolled and may become outdated.
Refer to electronic documents in the EDMS for current versions.
25504-100-3PS-NF00-F0002-00B
 Wheatstone Project LNG Plant Document No: WS1-0000-FGS-SPC-BEC-000-00102-000
Specification for Proprietary Cementitious Fireproofing Revision: 0
Revision Date: 13-Jan-2010

7.0 EXTERNAL TOPCOAT

The external topcoat, if required by the purchase order, shall be applied to the completed
and cured fireproofing in accordance with the Seller's written procedure and the coating
specifications. For shop applied fireproofing, the topcoat shall be applied, cured, and
inspected prior to shipment.

8.0 INSPECTION AND TESTING

8.1 Any defects disclosed by inspection shall be re-inspected after correction. Necessary
corrective actions for areas which do not meet the requirements of this Specification shall
be corrected at Seller's expense.

8.2 The surfaces to be fireproofed shall be divided into areas or units of production as a basis
for inspection. The inspection points shall be established as follows:

• Prior to the start of work

• Following installation of reinforcement materials
• Immediately prior to application of the fireproofing
• Following the application and curing of the fireproofing
• After application of the topcoat

8.3 The Seller shall provide on-site inspection. The following examinations shall be performed
by the Seller's inspector.

• Prior to using compressed air, the quality of the air downstream of the separator shall
be tested by blowing the air into a clean, white blotter or cloth for two minutes to
check for any contamination, oil, or moisture. This test shall be performed at the
beginning and end of each shift and at not less than four-hour intervals. The test
also shall be made after any interruption of the air compressor operation or as
required by the Buyer. The air shall be used only if the test indicates no visible
contamination, oil, or moisture. If contaminants are evident, the equipment
deficiencies shall be corrected and the air stream shall be retested. Separators shall
be bled continuously. All lines shall be tested individually prior to use.

• The nozzlemen shall be qualified to ACI Guide 506.3. Qualification testing shall be
subject to inspection, review and acceptance by the Buyer.

• Substrate must be clean and free of loose particulate matter. All coating must be
intact. Any discrepancies must be rectified before application of the fireproofing.

• Anchors shall be randomly tested to ensure sound welds by means of a hammer test.

• All reinforcement shall be inspected to assure conformance to approved design

sketches.

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Electronic documents, once printed, are uncontrolled and may become outdated.
Refer to electronic documents in the EDMS for current versions.
25504-100-3PS-NF00-F0002-00B
 Wheatstone Project LNG Plant Document No: WS1-0000-FGS-SPC-BEC-000-00102-000
Specification for Proprietary Cementitious Fireproofing Revision: 0
Revision Date: 13-Jan-2010

• Wet thickness shall be measured in accordance with ASTM E 605, before material
sets hard. On beams and columns, four sets of random measurements shall be
taken for each unit or for each 15 lineal meters (50 lineal feet).

• Visual inspection of fireproofing shall be performed to ensure no honey combing,

hollow voids, or other defects exist. Observations shall be made to insure that the
curing membrane, if utilized, was applied properly.

• The applied fire protection shall be free of defects such as excessive cracks, voids,
spalls, or any exposure of the substrate. The appearance and workmanship shall
conform to the mock-up.

8.4 The Seller shall furnish the necessary testing and inspection instruments, properly
calibrated and maintained. Such equipment shall be available for use by the Buyer in
conducting surveillance of the work.

8.5 Defects or damaged areas detected during assembly or handling shall be repaired in
accordance with procedures as permitted by the Buyer.

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Bechtel Confidential. © 2010 Bechtel Oil, Gas and Chemicals, Inc. All rights reserved.
Electronic documents, once printed, are uncontrolled and may become outdated.
Refer to electronic documents in the EDMS for current versions.
25504-100-3PS-NF00-F0002-00B