Doc. No.

: 7T04-CS-XER-MS-IF-0004
METHOD STATEMENT Rev. : 00
Date : 10 February, 2016
FIREPROOFING
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METHOD STATEMENT

Fireproofing

COMPANY / TPI : EGYPTIAN REFINING COMPANY (TAKRIR) S.A.E

CONTRACTOR : GS ENGINEERING & CONSTRUCTION

SUBCONTRACTOR : XERVON EGYPT S.A.E

PROJECT NAME : ERC REFINERY PROJECT

WORK PACKAGE : FIREPROOFING WORKS

SITE : MOSTOROD, EGYPT

00 10 Feb, 2016 For Approval Hosny Mohamed Hazem Wassel

REV. DATE DESCRIPTION PREP’D CHK’D CHK’D APPR’D
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INDEX

1. PURPOSE

2. SCOPE

3. RESPONSIBILITIES

4. ABBREVIATIONS

5. REFERENCE DOCUMENTS

6. GENERAL GUIDANCE

7. APPLICATION PROCEDURE

8. REPAIR PROCEDURE

9. INSPECTION MEASURES

10. HEALTH AND SAFETY REQUIREMENTS

11. ATTACHMENT
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1.0 PURPOSE

This method statement is to define and ensure a system of control and monitoring of all
activities interfaces and responsibilities relating to applying of fireproofing system for ERC
Project in order to meet project specifications requirements for a fire protection rate of 2 hrs.

2.0 SCOPE

This procedure covers the surface preparation of the beams, columns, equipment skirting &
installation of the fireproofing material.

3.0 RESPONSIBILITIES

3.1 The QA/QC Representative shall be responsible for ensuring the correct application of
this procedure.

3.2 The Construction Coordinator shall be responsible to the Project Manager for the
overall implementation of this procedure.

3.3 The Field Superintendent shall be responsible for achieving the stage acceptance of
the Quality Control Inspection and Test Plan.

Delegation
The actions described in this method may be delegated to personnel with sufficient
training and experience to complete the task.

“RESPONSIBILITIES SHALL NOT BE DELEGATED.”

4.0 ABBREVIATIONS

ERC Egyptian Refining (TAKRIR) Company S.A.E. (Company)

Mostorod, Egypt
GSE&C GS Engineering and Consultation Corp. (Contractor)
PMC Project Management Consultancy Worley Parsons (Consultant)
XER XERVON Egypt
ITP Inspection & Test Plan
TDS Technical Data Sheet
MSDS Material Safety Data Sheet
SFRM Spray-Applied Fire Resistive Material
ID Inner diameter
Min Minimum
Deg Degree
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5.0 REFERENCE DOCUMENTS

 GSE&C Design Specification for Fireproofing 7T04-CI-00-TS-003; Design Specification for

Fireproofing.
 XER Inspection and Test Plan and Inspection Record
 UL 1709; Standard for Rapid Rise Fire Tests of Protection Materials for Structural Steel.
 ANSI/UL 1709, Design No. XR730; Fire-resistance Ratings
 Products TDSs
 Products MSDSs

6.0 GENERAL GUIDANCE

6.1 Material Requisition and Storage

All materials will be approved by Company through Material Acceptance Sheet (MAS)
submittal; where all TDS (Technical data sheet), MSDS (Material safety data sheet)
and MTCs (Material test certificates) will be associated with the MAS submittal.

It shall be the responsibility of the appropriate Area Field Superintendent to authorise

the requisition of materials to be used for the fireproofing works where all materials
have to be checked before usage.

Material storage, at any case, shall be stored as per product TDS & MSDS and/or
manufacturer recommendation until ready for use.

In general, material shall be stored off the ground, undercover, and away from wet or
damp surfaces or areas of very high humidity. Storage temperatures are not critical as
long as dry conditions are maintained.

6.2 Weather protection

During application, a minimum ambient temperature of 4˚C and maximum 45˚C must
be maintained, relative humidity must be greater than 50% and substrate temperature
is above dew point by 2˚C.

In hot dry conditions, particularly where strong radiant sunlight, strong winds or both
are present, it is necessary to protect the product from rapid evaporation of its
moisture content.

The products may however be subjected to high temperatures and low relative
humidity provided they are protected from excessive drying since excessive
evaporation of water does not permit full hydration of the binders and full strength of
the product may not be developed.

Measures that mitigate excessive drying include:

 Shielding the work area from direct sunlight.

 Wrapping exposed product with polyethylene sheets to slow evaporation.
 Wrapping exposed products with damp burlap cloth (Hessian cloth) to slow
evaporation.
 Working in shaded areas, moving with the sun.
 Working in the evening or early morning.
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 Applying a light spray of water to the exposed product. Repeat this as often as
necessary to maintain a damp product for at least 48 hours after application.
This may take up to 3 to 5 days in extreme conditions.

7.0 APPLICATION PROCEDURE

7.1 Corrosion Protection

Surface to be fireproofed shall be primed / painted or shall be galvanized to ensure

long term corrosion protection. If any, repairs and touch up is required for damaged
areas, shall be done prior to fireproofing work start (activity by others – coordination
with contractor is required where applicable).

7.2 Surface Preparation

Surfaces to be fireproofed, shall be cleaned by fresh water so that they are free from
oil, grease, dirt, loose paint, dusts etc.
Masking and protection of adjacent surfaces not to be fireproofed shall be carried out
prior to commencement of works.

7.3 Key Coat

A key coat improves bonding between coated steel surface and fireproofing material,
and insures the durability of the system.

 At any case, use compatible material to ISOLATEK MII (Cementitious Spray –

Applied fire resistive material) and applied primer.
 Apply one coat of a ready mixed latex emulsion product and allow drying to
provide the enhanced bond to ISOLATEK MII wet spray.
 OR, use a mix of ISOLATEK MII with an admixture specially formulated to be
used with cement based mortars to improve adhesion, at this case mix a bag
of ISOLATEK MII with fresh water and admixture to the ration 1:1; Apply the
mentioned mix using fireproofing spray machine or Tyrolean Gun so that it
covers 40m² to the steel surface to obtain a durable tie coat.

7.4 Wire Mesh Installation

Wire mesh is used as reinforcement for the fireproofing applied system, installed at
site using hand tools.

For steel structure; Sections up to and including 200mm x 200mm are normally
protected by the solid fill method and sections greater than this are normally protected
by the profile (contour) method of application using 25mm x 25mm or 50mm x 50mm
Hexagonal, twisted and galvanized wire mesh of minimum diameter 0.9mm.

 Profile (contour) Method:

Attach wire mesh to previously fixed nuts or pins & washers, using wire ties and
ensure that mesh is pulled away from the steel surface to lie substantially within the
mid third of the required fireproofing thickness.
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 Solid fill Method:

The wire mesh may be applied after the web has been solid filled with fireproofing
material OR the mesh may be attached to the previously fixed nuts or pins & washers
and loosely fitted over the flange tips so as to be in the mid third of the applied
thickness which in this case is measured from the flange faces and tips (fireproofing
material may then be sprayed through the mesh to fill the web and cover the
remaining prepared steel surfaces).

For vessels skirts; vessel skirts less than 20m², same wire mesh as for steel
structure to be used. For vessel skirts larger than 20m², use 50mm x 50mm
Hexagonal, twisted and galvanized wire mesh of minimum diameter 0.9mm OR
100mm x 100mm square welded wire mesh (Same procedure to be applied for mesh
installation).

At any case, keep a minimum of 50mm overlap at all joins of wire mesh and no more
than 3 layers overlapped at a point. Overlaps on beams and columns, shall be on
flange face not adjacent to the web.

7.5 Fireproofing Spray Application

Fireproofing material, ISOLATEK Type MII (Lightweight Cementitious) is a single

pack, factory controlled SFRM tested and developed for fire protection of external
structural steel components such as tanks, support legs and saddles, pipe racks,
vessel skirts, sphere legs, etc.

For a fire protection rate of 2 hours as per project specification and according to UL
design ANSI/UL 1709 XR730 for ISOLATEK MII, a recommended minimum thickness
of 32.5mm is required following the steps of preparation and application of the
fireproofing material as instructed by the product application guide and TDS.

 Product Mixing:

- Use suitable equipment mixer/pump as per manufacturer recommendation during

mixing and spray application of ISOLATEK MII (PUTZMEISTER spraying equipment
type S5 or SP11).

- Mixer: A paddle or ribbon-type mortar mixer with safety cover and provision for quick
dumping of mix directly into the pump hopper, with 227 liters minimum capacity of
operating speeds of 35 to 40 RPM will be used.

- The product is mixed by first adding potable water to the mixer and then product.

- Each bag requires 16 to 20 litres of potable water.

- Mix for three (3) minutes. Providing that mix is almost continuous, the next batch can
be prepared without washing out the mixer.

- In a multiple bag mix, the mix time begins after the last bag has been added to the
mixer.
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 Spray Application:

The application of the ISOLATEK MII material shall be in accordance with the
manufacturer requirements and instructions as follows:

- Pump: A rotor stator type, open throat, screw feed pump with minimum “No. 4” soft
rubber stators will be used.

- Hose set-up: Suitable high pressure plaster types hoses will be used in conjunction
with screw-on type connect/disconnect hose couplings that do not restrict the product
flow. Steel tapered reducers will be used when a reduction in hose is necessary.

- Nozzle: The spray nozzle assembly will consist of 25 mm ID minimum aluminium pole
with a blow-off type nozzle cap. Nozzle orifice will be 13 mm diameter.

- Nozzle distance: The distance between the nozzle and substrate will vary between
152mm and 457mm, to be adjusted during work progress relatively to the type of
equipment and nozzle used.

- Nozzle pressure: A minimum of compressed air volume of 420 litre / min and a min.
pressure of 50 psi will be used to reach even thickness build, texture and proper
density.

- Spray Application: The mortar will be applied with single or successive coats of a
maximum thickness of 15 mm by pass until reach the total thickness required for fire
rate as defined by project specification and according to UL/BS design for the material
and substrate properties. The material reach the spray gun where, with pneumatic
impulsion will spray the mortar on the surface. The recommended tolerance that shall
be applicable on site is +/- 2 mm – to be checked using needle gauge for thickness
inspection.

- Multiple coats: For multiple coats application, the preceding layer is left to stiffen, then
textured or scratched. After about 48 hours the subsequent coat to be applied. If the
surface of the preceding coat becomes dry, it will be moistened with water prior to
applying further coats. The exact required time between multiple coats will be
subjected to the environmental conditions assessment at the time of application.

7.6 Finishing

 It is recommended that ISOLATEK MII is trowel smooth finished once the

specified thickness has been applied or within 48 hours prior to receive top
coat to obtain a final smooth homogeneous appearance, sharp edges to be
chamfered using sand paper.
 All cementitious fireproofing material will be provided with a top coat.
 Insure fireproofing material is dry and ready for top coat, apply any repair to
the surface using same material of fireproofing prior to top coat application.
 Apply a finish coat of a compatible material with the ISOLATEK MII using
brush or roller. The top coat material is to form a durable, protective,
waterproof membrane with a proper surface view.
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7.7 Sealant

 All the fireproofing to steel interface shall be fully sealed joints against the
entrance of moisture with a sealant.

- The sealant to be used, must be adhere to both cementitious and steel surfaces and
able to withstand contentious contact with solutions of potassium carbonates,
vanadium salts, hydrocarbons and grease.

- Cut a groove of 8mm x 8mm at all steel to fireproofing interface.

- Fill the groove with the sealant material.

8.0 REPAIR PROCEDURE

 Cut away and remove any loose cementitious material and chamfering the surrounding
area to sharp edges (cut the existing edges to form 45 deg. slopes).
 Where mesh reinforcement is exposed, clear the material away from the mesh.
 If damage has resulted in mesh failure, totally remove the effected mesh and reinstate with
new mesh ensuring that a min of 50mm overlap onto the original mesh is achieved and
that it is secured by use of wire ties. Insure correct mesh position.
 If the existing cementitious material has become very dry, dampen the surfaces.
 When batch is dry, reinstate any previously applied surface treatment
 Go through the normal application steps for material application.

9.0 INSPECTION MEASURES

 Refer to ITP plan for inspection and control measures for fireproofing activities.

10.0 HEALTH AND SAFETY REQUIREMENTS

 Refer to MSDS for safe material preparation, usage and selection of proper required PPE
(personal protective equipment).
 Scaffolding shall be complied with safety regulations and Company requirements.
 Refer to Task Risk Assessment of each activity for safe work condition.
 All potential sources of ignitions shall be strictly controlled.
 All Material safety data sheets (MSDS) shall be dressed in the location of the working area
and communicated to the working persons.
 HSE Representative is required at site while the activity is continued.
 Housekeeping will be properly observed before, during and after fireproofing activities.

11.0 ATTACHMENT

 ANSI/UL 1709, Design No. XR730.

 ISOLATEK Type MII (Industrial Spray-Applied Fire Resistive Material) TDS and MSDS.
 PUTZMEISTER spraying equipment S5 and SP11 brochures.