Issue | 01 | March 2017

BW11 Fire Rated Ductwork

Applications
and
Technical
Manual
 Introduction

Firespray International Limited is internationally recognised in the design and manufacture of

an extensive range of specialist fire and acoustical systems into a diverse range of industrial
disciplines encompassing the general construction, transportation, power generation and
bespoke manufacturing industries.

Accredited to ISO 9002 and ISO 9001:2000, Firespray International is committed to the highest
standards in products development, manufacture and customer support.

Since its formation in the early nineties, Firespray International Ltd has become recognised as
a world authority in the design and manufacture of Fire Ducting Systems under the brand
name FLAMEBAR.

With a primary manufacturing base in the UK, Firespray International Ltd has now developed
a highly specialised international Licensees network encompassing the world.

This Manual has been produced for everyone associated with the design and installation of
fire rated ductwork systems and illustrates how to satisfy the requirements of the regulatory
bodies. It also clearly emphasises our own commitment to fire safety.

FLAMEBAR BW11 FIRE RATED DUCT SYSTEMS SATISFY ANY REQUIREMENT FOR FIRE RATED
DUCTWORK FOR VENTILATION, KITCHEN OR SMOKE EXTRACT APPLICATIONS.

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Contents
1. Testing Requirements - BS 476 Part 24 (1987) and ISO 6944 (1985) 4

2. Fire Rated Ductwork - Analysis and Performance 6

2.1 FLAMEBAR BW11 - Single Source Responsibility - Certificate of Conformity 6

2.2 FLAMEBAR BW11 - Flexibility in Design 6
2.3 FLAMEBAR BW11 - Construction of Fire Duct 7
2.4 FLAMEBAR BW11 - System Integrity - Ancillary Components 7
2.5 FLAMEBAR BW11 - Panel Construction 8
2.6 FLAMEBAR BW11 - Air Temperatures at Various Distances from Duct 9
2.7 FLAMEBAR BW11 - Supports and Hangers 10

3. Fire Rated Ductwork - “When and Why” 12

4. Smoke Extract Duct System 13

5. Non-Domestic Kitchen Extract Duct System 14

6. Basement and Enclosed Car Park System 15

7. Escape Route Ducts 16

8. Basement Smoke Extract System 17

9. Dual Ventilation/Smoke System 18

10. Pressurisation Duct System 19

11. High Risk Areas 20

12. Penetration Seals between Fire Compartments 21

13. Standards 22

14. System Advantages 23

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 1. Test Requirements
British Standard 476 Part 24 (1987): ISO 6944 (1985)

BS 476 Fire Tests on building materials and structures: Part 24 (1987) Method for
determination of the fire resistance of ventilation ducts

ISO 6944 (1985) Fire resistance tests - Ventilation ducts

The purpose of BS 476 Part 24 (1987) and ISO 6944 (1985) is to measure the ability of a
ductwork system to resist the spread of fire from one fire compartment to another without
the aid of fire dampers. It should be noted that the test relates to a complete ductwork
installation and therefore joints, supports and the fire stopping through the furnace wall all
form an integral part of the test.

Aluminium Melts
Fibre Glass Melts

Furnace Temperature Curve as

Specified in BS 476 Part 24
(1987) & ISO 6944 (1985)

Giving temperature rise as a function of time for all British Standard 476 Part 24 (1987) and
ISO 6944 (1985) Fire Tests.

4
Requirements of British Standard 476 Part 24 (1987): ISO 6944 (1985)

The fire resistance of Ventilation Ductwork shall, according to the Standard, be expressed in
minutes of duration of heating until failure occurs according to one or more of the following
criteria:

1. Stability 2. Integrity 3. Insulation

Criteria of Failure

Stability: Stability failure shall be deemed to have occurred in duct type A within the furnace
and in duct types A and B outside the furnace when the duct collapses in such a manner that
the duct no longer fulfils its intended function.

Integrity: The presence and the formation of cracks, holes or other openings outside the
furnace through which flames or hot gases can pass shall constitute integrity failure.

Insulation: Insulation failure shall be deemed to have occurred when the temperature rise
above initial ambient temperature on the unexposed surface of the test specimen outside the
furnace exceeds either:

1. 140oC as an average value, or

2. 180oC as a maximum value.

For kitchen extract duct type A, these temperatures rise limits also apply to the inside surface
of the duct within the furnace.

Definitions of Types A & B Fire Exposure

The testing standard differentiates between types of fire exposure; two classifications apply as
detailed below.

Fire Outside - Duct Type A

Fire Inside - Duct Type B

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 3. Fire Rated Ductwork
Analysis and Performance

3.1 FLAMEBAR BW11 - Single Source Responsibility - Certificate of Conformity

3.2 FLAMEBAR BW11 - Flexibility in Design
3.3 FLAMEBAR BW11 - Construction of Fire Duct
3.4 FLAMEBAR BW11 - System Integrity - Ancillary Components
3.5 FLAMEBAR BW11 - Panel Construction
3.6 FLAMEBAR BW11 - Air Temperatures at Various Distances from Duct
3.7 FLAMEBAR BW11 - Supports and Hangers

3.1 Single Source Responsibility - Certificate of Conformity

When considering the use of Fire Resistant Ductwork, issues such as Single Source
Responsibility and Certificates of Conformity are often overlooked. When specifying
FLAMEBAR BW11 you are assured that every process from design to installation is directly
controlled.

Single Source Responsibility means exactly what it states, that from design through
manufacture, spray coating and installation there is a single source responsibility.
Furthermore, once all the installation is complete and all contractual commitments are
fulfilled a Certificate of Conformity is issued to the client. This confirms the periods of fire
resistance installed and confirms compliance with the relevant criteria of BS 476 Part 24
(1987) and ISO 6944 (1985). This document underlines our commitment to providing the best
and ultimately most “fire safe” installations available.

3.2 Flexibility in Design

FLAMEBAR BW11 offers complete flexibility in design - rectangular, flat oval and circular ducts
are available. The construction of the initial galvanised sheet steel duct means that all
FLAMEBAR BW11 Fire Ducts have normal standards of air tightness and are therefore easily
capable of being successfully tested.

As well as profile flexibility as depicted in the previous illustrations, FLAMEBAR BW11 Fire
Ducts can also be supplied as detailed below:

Single Sided Two Sided Three Sided

Four Sided Circular Flat Oval

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3.3 Construction of Fire Rated Duct
FLAMEBAR BW11 Fire Duct is constructed from galvanised sheet steel manufactured to an
enhanced standard, then degreased and sprayed with FLAMEBAR BW11 which is specially
formulated water based compound. This contains selected mineral fillers in a low permeability
elastomeric binder to a thickness of approximately 1mm to give a finished product which has
been successfully tested for international use under Cellulosic Fire Conditions in excess of 4
hours duration. Ductwork is produced in sections and is assembled on site utilising tested
fireproof gaskets/sealants.

The unique properties of FLAMEBAR BW11 has enabled us to design a low density, highly
durable material which accommodates induced stress arising from extreme and varying
conditions e.g. Climatic Moisture and Structural Loading Variations, and the effect of thermal
shock during a fire.

The completed system has been completed to BS 476 Part 24 (1987) and ISO 6944 (1985) up
to temperature of 1133oC, thereby facilitating complete design freedom should a fire
engineering approach be adopted.

3.4 System Integrity - Ancillary Components

FLAMEBAR BW11 FLAMEBAR BW11
Fire Resistant Attenuators Fire Resistant Volume Control Dampers

FLAMEBAR BW11 FLAMEBAR BW11

Fire Resistant Access Doors Cable and Pipe Enclosures

Some of the additional features that can be incorporated in FLAMEBAR BW11 Fire Duct
Systems;

1. Access Doors 4. Cable and Pipe Enclosures

2. Control Device Housings 5. Penetration Seals
3. Volume Control Dampers 6. Protection can be applied to fans, silencers, etc.

7
 3.5 Panel Construction
FLAMEBAR BW11 ductwork can either be constructed in flanged lengths of duct, which are
then bolted together to make a run of ducting, or in panel form. This construction is especially
useful for ducts of large cross-section and can be used on any size of duct up to 25m x 3m.

Benefits of the Panel Construction System

 Tested for up to 4 hours Stability, Integrity & Insulation to BS 476 pt 24 (1987) and
ISO 6944 (1985) for Ventilation Fire Duct, Smoke Duct & Kitchen Extract ductwork.
 When insulation rating is required panels are pre-insulated at the factory.
 Smooth cleanable internal finish.
 Total flexibility in the design and construction of the duct.
 Can be sent to site “flat packed” ready to bolt up.
 Lightest fire duct system available.

The panels are delivered to site pre-coated on the outside face with FLAMEBAR BW11 and are
then bolted together incorporating FLAMEBAR intumescent gasket strip to form the required
duct cross-section.

Examples of Panel Configurations

‘U’ and Panel Construction

4 Panel Construction
‘U’ Panel Construction

‘L’ Panel Construction

8
3.6 Air Temperatures at Various Distances from Duct
Compartment walls and floors will have a prescribed fire resistance in terms of stability,
integrity and insulation for between 30 and 240 minutes. It is therefore essential for fire
security, that where compartmentation boundaries are penetrated by fire duct, the fire
separation and the performance criteria of the penetration wall or floor is maintained, and
that the duct should not act as a conduit along which fire may spread to other areas.

In all cases, the time period for stability and integrity should be at least equal to that required
by the penetration element. However, controlling Authorities and engineered solutions have
in many circumstances waived the insulation requirement. If the ductwork is within the first
compartment (see example) it will not need to be insulated and if the fire duct has not been
fire insulated for a give period to BS 476 Part 24 (1987), sufficient distance must be
maintained between the fire duct and any adjacent combustible material. BS 5588 Part 9,
Appendix Clause A4, recommends a minimum of 500mm be maintained for bare metal
ductwork.

The graph below gives the air temperature, taken at various distances away from our
FLAMEBAR BW11 fire duct. It should be noted that the insulation failure temperature, as per
BS 476 Part 24 (1987), is of a minimum of 140oC, plus ambient temperature, i.e.
approximately 160oC.

FLAMEBAR Solution When Lower Insulation Temperature Required

All FLAMEBAR BW11 Fire Ducting has been fully tested to BS 476 Part 24 (1987) and ISO 6944
(1985) for stability and integrity up to 4 hours. However, where lower installation
temperatures are required due to ducting being rated the same as the smoke extract fan or a
fire engineering consultant having determined a fire engineering solution, we are able to offer
our FLAMEBAR BW11 product, either on its own or with the addition of various thicknesses of
insulation depending upon the insulation fire rating required.

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 Smoke Exhaust Duct Test in Accordance with BS 7346 - Fire Inside Duct

Minimum Periods of Fire Resistance for Fire Rated Ductwork

Example showing a typical fire duct run passing through different fire rated compartments

From the example, it can be seen that when the fire duct passes from the 2nd to the 3rd fire
compartment, the fire resistance of the duct increases in line with the rating of the fire
compartment wall. This rating is not reduced in the 4th compartment, despite the reduced
rating of the fire compartment wall between the 3rd and 4th fire compartments.

Important Note

If the fire duct is for extracting smoke, it must also maintain a minimum of 75% of its overall
cross-sectional area over the total length of the duct, including the 1st fire compartment.
Therefore smoke extract ductwork in the 1st fire compartment must always be tested to BS
476 Part 24 (1987) for stability and integrity only.

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3.7 Supports and Hangers
It is known that tensile strength of steel reduces with temperature, it has been calculated and
tested by the Loss Prevention Council that based on the original strength of steel for supports
of 430N/mm2. Fire duct supports should be sized based on:

Fire Duct rated for 60 minutes 925oC (1697oF)

Tensile strength of 15N/mm2

Fire Duct rated for 120 minutes 1029oC (1884oF)

Tensile strength of 10N/mm2

Fire Duct rated for 240 minutes 1133oC (2071oF)

Tensile strength of 6N/mm2

Weight of FLAMEBAR BW11 Fire Duct

Total weight of up to 2 Hour Fire Duct without insulation = 10.98 kg/m2

Total weight of up to 2 Hour Fire Duct with 50 mm insulation = 16.23 kg/m2
Total weight of up to 2 Hour Fire Duct with 100 mm insulation = 21.48 kg/m2
Total weight of up to 4 Hour Fire Duct without insulation = 14.12 kg/m2
Total weight of up to 4 Hour Fire Duct with 50 mm insulation = 19.37 kg/m2
Total weight of up to 4 Hour Fire Duct with 100 mm insulation = 24.62 kg/m2

Above weights are based on 1000mm x 1000mm typical standard ductwork per linear metre.

When designing and testing Fire Resistant Ductwork it is critical that the reduction in tensile
strength of steel under fire load is given adequate consideration. This applies to hangers
(studding) and bearers, but it is equally important that due consideration is given to the
performance of the fixing system under fire load.

It must be recognised that the “pull out” load of an anchor under fire conditions is significantly
less than at ambient temperature. By specifying FLAMEBAR BW11 you can be confident that
these issues have been adequately addressed.

Typical Anchor and Hanger Sizes Required for 2 hour Stability and Integrity
FLAMEBAR BW11 Smoke Duct
Max test load Size of
Total weight
Duct area that Hilti HKW anchor &
per metre Bearer Weigh on Weight on
Duct Size per metre anchor will hanger used
run of duct Spacing mm each bearer each anchor
run withstand in a to provide
+BW11
fire situation added safety
Sum of 2 30 kg
1.2m2 14.4 kg 1500 21.6 kg 10.8 kg M8
sides 600 = 6mm HKD
Sum of 2 30 kg
1.6m2 19.3 kg 1500 28.95 kg 14.5 kg M8
sides 800 = 6mm HKD
Sum of 2 30 kg
2.4m2 33.65 kg 1500 50.7 kg 25.2 kg M8
sides 1200 = 6mm HKD
Sum of 2 40 kg
3.2m2 51.1 kg 1500 76.6 kg 38.3 kg M8
sides 1600 = 6mm HKD
Sum of 2 80 kg
4.0m2 65.7 kg 1500 98.5 kg 49.5 kg M10
sides 2000 = 10mm HKD
Sum of 2 80 kg
sides 3000 6.0m2 98.7 kg 1500 148 kg 74 kg M12
= 10mm HKD
Sum of 2 120 kg
sides 4000 8.0m2 131.5 kg 1500 198 kg 98.5 kg M12
= 12mm HKD
Sum of 2 300 kg
sides 5000 10.0m2 202 kg 1500 303 kg 152 kg M16
= 16mm HKD

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 4. Fire Rated Ductwork
“When & Why”
One of the most important factors taken into consideration when designing and constructing
a building is effective compartmentation to limit fire spread throughout the building. Under
normal circumstances compartmentation is maintained by fire dampers within ductwork
systems. However under certain circumstances fire dampers should not be used and the
ductwork itself must provide the same levels of fire resistance as that afforded by the
compartment wall or floor.

Ductwork systems which do not normally contain fire dampers are as follows:

1. Smoke Extract Ducts

2. Car Park Extract Ducts
3. Pressurisation Ducts
4. Kitchen Extract Ducts

Any ductwork system that is intended to operate or has special use under a fire condition and
cannot therefore utilise fire dampers will require a fire rating to match the compartmentation
it passes through.

Ventilation and extract systems in applications which have special or operational effect under
fire conditions are as follows:

 Smoke Extract Duct System

 Non-Domestic Kitchen Extract System

 Basement and Enclosed Car Park System

 Escape Route Ducts

 Basement Smoke Extract Duct System

 Dual Ventilation/Smoke Extract System

 Pressurisation System

 High Risk Areas

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5. Smoke Extract Duct System
Ductwork used in smoke extract systems should normally be rated for stability, integrity and
insulation, at least equal to the compartment wall through which it passes. (Approved
Document B Fire Safety, Notes To Table A1, Appendix A).

Smoke extract ductwork must retain at least 75% of its cross sectional area, both in the fire
compartment as well as in adjacent compartments. If the duct is contained within a dedicated
shaft or there is at least 500mm separation between the ductwork and combustible materials
(e.g. in car parks) stability and integrity ratings may be required within the area to be
protected.

SUITABLE FIRE RATED

FAN TESTED TO BS 7346 ROOF PLANT ROOM

MOTORISED
SMOKE/FIRE
DAMPER AT
EACH FLOOR

PENETRATION
ESCAPE SEAL
OFFICE CORRIDOR

ESCAPE SERVICE
OFFICE CORRIDOR SHAFT

FIRE RATED WALLS FIRE RATED FLOORS NON-FIRE RATED WALLS

IN THE DIAGRAM

Office extract ductwork shown must be suitable for clearing smoke within the compartments and normally
rated for 1 hour for stability and integrity to resist hot smoke and fire from inside (Type B). Insulation fire rating is not
required in the first compartment.

Where the office extract duct crosses the escape corridor shown it must maintain stability, integrity and
insulation fire rating for the same period of time as the compartment through which it passes and this may be
required for the remainder of the ductwork route through the building to outside.

In some circumstances insulation requirements may be waived or varied by the regulatory authority if there are no
combustible materials within 500mm of the duct, such as in the plantroom shown (BS 9999:2008 Ref. W.4).

In order that the 75% cross sectional free area criteria is maintained, fire rated ductwork would be used within the
service shaft requiring stability and integrity shown However, if there are combustible materials
within 500mm of the duct, insulation would still be needed.

Building Regulations and BS 476-24/ISO 6944 stipulate that all fire rated ductwork should be tested and installed to
comply with the full ‘cellulosic’ time/temp fire test curve (ISO 834 Fire Curve). A fire engineered solution designed by
a qualified fire engineering consultant for lower smoke temperature may be allowed by the regulatory authority, thus
reducing the insulation requirement. However, the duct must still be tested and installed to maintain stability and
integrity to the full test temperature.

All fire rated ductwork and penetration seals must be tested to BS 476-24/ISO 6944 by a recognised NAMAS/UKAS
accredited laboratory.

Note: Final approval must always be obtained from the Local Building Control Officer/Fire Department prior to
commencement of construction.

13
 6. Non-Domestic Kitchen Extract
Non-domestic kitchen extract ductwork is sometimes referred to as grease ducting and should
be tested for Type A fire outside and Type B fire inside. Both tests are required to prevent
flammable grease from either catching fire when it passes through an adjacent area or, if the
grease itself is already alight, causing a fire to start within the adjacent area by radiant heat.

Non-domestic kitchens must have separate and independent extract systems (BS 9999:2008
Clause 33.4.7). Fire dampers should not be used in kitchen extract ductwork (BS 9999:2008
Clause 33.4.3.2 and 33.4.4.2). Access doors must be installed at three metre intervals where
possible (BS 9999:2008 Clause 33.4.7) and internal surfaces must be smooth to enable easy
cleaning of the grease. Care must be taken to ensure combustible deposits in the duct cannot
ignite in adjacent compartments.

SUITABLE FIRE RATED

ROOF PLANT ROOM
FAN TESTED TO BS 7346

PENETRATION
SEAL

KITCHEN EXTRACT
ESCAPE DUCTWORK

OFFICE CORRIDOR
FIRE RATED
ACCESS DOORS

SHAFTCONSTRUCTED
TO METHOD 2 OF
ESCAPE SERVICE BS 9999
OFFICE CORRIDOR SHAFT

ESCAPE
KITCHEN CORRIDOR

FIRE RATED WALLS FIRE RATED FLOORS NON-FIRE RATED WALLS

IN THE DIAGRAM

Kitchen extract ductwork presents a particular hazard in that combustible deposits such as grease are likely to
accumulate on its internal surfaces. Therefore, the Ductwork should resist fire from inside (Type B) and must be rated
for stability, integrity and insulation, for the same period of time as the compartment through which it passes shown

A fire in an adjacent compartment through which the kitchen extract ductwork is passing, could initiate a fire within
the ductwork, which in the absence of fire dampers might prejudice the safety of kitchen occupants, it should also be
tested to fire outside (Type A) with the additional requirement that the internal surface of the ductwork within the
compartment must meet the insulation criteria.

In some circumstances insulation requirements may be waived or varied by the regulatory authority, if the duct
passes through an area where fire cannot be present shown such as a protected shaft. However, stability
and integrity must still be maintained for the relevant period of time.

Ductwork within the kitchen (the first compartment) does not have to be fire rated shown

All fire rated ductwork and penetration seals must be tested to BS 476-24/ISO 6944 by a recognised NAMAS/UKAS
accredited laboratory.

Note: Final approval must always be obtained from the Local Building Control Officer/Fire Department prior to
commencement of construction.

14
7. Basement & Enclosed Car Park
Basement and enclosed car parks require an extract ductwork system suitable for clearing
smoke and fumes. Either natural or mechanical methods may be used to ventilate basement
and enclosed car parks.

Natural ventilation requires the permanent opening of the floor area, at 2.5%, to provide a
through draft (Approved Document B, Fire Safety, B3 Section 11.5). Mechanical ventilation
must provide six air-changes per hour in normal conditions and ten in the event of a fire.
Extract points must be arranged so that 50% are at high level and the remainder at low level
(Approved Document B, Fire Safety, B3 Section 11.6).

All components of the system must have a minimum melting point of 800°C (Approved
Document B, Fire Safety, B3 Section 11.6). Fire dampers should not be used in any basement
or enclosed car park extract system (BS 9999:2008 Clause 33.4.4.2). Ductwork must retain at
least 75% of its cross sectional area - in the fire compartment and in adjacent compartments.

NON RETURN DAMPERS FANS TESTED TO BS 7346 DESIGNED

TO OPERATE AT 300OC FOR 1 HOUR
TO RUN AT 50% OF THE NORMAL
SMOKE VOLUMES AND CAN OPERATE
SINGULARLY AND SIMULTANEOUSLY.
INDEPENDENT POWER SULPPLY IN
VOID THE EVENT OF FAILURE OF THE MAIN
SUPPLY.
PENETRATION SEAL

ROOF PLANT ROOM CAR PARK EXTRACT

DUCTWORK

OFFICE

ACCESS TO
CAR PARK

CAR PARK

FIRE RATED WALLS FIRE RATED FLOORS NON-FIRE RATED WALLS

IN THE DIAGRAM

The car park extract ductwork shown must be suitable for clearing fumes and smoke from within the car park
and normally rated for a minimum of 1 hour for stability and integrity to resist hot smoke and fire from inside (Type
B). All components of the ductwork system must have a minimum melting point of 800°C and therefore aluminium
grilles and fixings etc are not permitted.

Where the extract leaves the car park and crosses into another area shown it must maintain stability, integrity
and insulation fire ratings for the same period of time as the compartment through which it passes. In some
circumstances insulation requirements may be waived or varied by the regulatory authority if there are no
combustible materials within 500mm of the duct, such as in the void before the plantroom shown (BS
9999:2008 Ref. W.4).

In the area shown the plantroom may have been constructed as a total fire rated compartment. However, in
order that 75% cross sectional free area is maintained fire rated ductwork would be used requiring stability and
integrity. If combustible materials were within 500mm of the duct insulation would also be required.

All fire rated ductwork and penetration seals must be tested to BS 476-24/ISO 6944 by a recognised NAMAS/UKAS
accredited laboratory.

Note: Final approval must always be obtained from the Local Building Control Officer/Fire Department prior to
commencement of construction.

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 8. Escape Route Ducts
Escape route ducts are any duct crossing an escape corridor. In accordance with BS9999:2008,
clause 33.4.2, escape route ducts must be fire rated.

NON FIRE RATED DUCT FIRE DAMPER

PLANT ROOM
OR
OFFICE
RISER SHAFT
AT LEAST ONE FIRE AND
SMOKE DAMPER WILL BE
REQUIRED IF EITHER SIDE
OF ESCAPE CORRIDOR IS
CONSTRUCTED WITH
NON FIRE RATED DUCT.
PRESSURED FRESH
AIR SUPPLY DUCT TO
DUCTWORK IN ESCAPE
ESCAPE LOBBY
CORRIDOR MUST BE
FIRE RATED CLEANERS
ROOM

OFFICE

WHERE DUCT CROSSES

ESCAPE THE ESCAPE CORRIDOR
CORRIDOR STABILITY, INTEGRITY
AND INSULATION WILL
BE RQUIRED

NON FIRE
RATED DUCT
ESCAPE
NON FIRE LOBBY
RATED DUCT

FIREMAN
LIFT
STAIRWAY LIFT

FIRE RATED WALLS FIRE RATED FLOORS NON-FIRE RATED WALLS

IN THE DIAGRAM

The pressurised air supply duct shown from the fire rated plantroom above crosses the cleaner’s room and the
escape corridor to provide air to the escape lobby. Pressurisation ductwork systems are dealt with in full on page 21,
but it should be noted that where any type of fire rated duct crosses the escape corridor it will require stability,
integrity and insulation shown for the same period of time as the compartment through which it passes.

Both the normal ventilation supply duct and extract duct follow a route from the riser shaft through the office using
fire dampers and galvanised sheet steel duct (method 1 of BS 9999:2008) shown Where the ducts cross
and run in the escape corridor shown the duct must be fire rated and will require stability, integrity and
insulation for the same period of time as the compartment through which it passes.

It will also require at least one fire damper if either side of the escape corridor is constructed with non fire rated duct.

All fire rated ductwork and penetration seals must be tested to BS 476-24/ISO 6944 by a recognised NAMAS/UKAS
accredited laboratory.

Note: Final approval must always be obtained from the Local Building Control Officer/Fire Department prior to
commencement of construction.

16
 9. Basement Smoke Extract System
A basement smoke extract system consists of smoke outlets/vents to provide a route for heat
and smoke to escape to the open air.

Either natural or mechanical means may be used to ventilate smoke/heat from basements.
Where a system of mechanical ventilation is used a sprinkler system must be fitted - Approved
Document B, Fire Safety B5, section 18.13.

The air extraction system should give at least 10 air changes per hour - Approved Document B,
Fire Safety B5, section 18.14. The fire duct must be constructed to resist water impingement
from any sprinkler system.

FAN TESTED TO BS 7346 TO 300OC

FOR AT LEAST 1 HOUR AND OPERATES
AUTOMATICALLY ON ACTIVATION OF
ATTENUATOR THE SPRINKLER SYSTEM.
(FIRE RATED)

ROOF PLANT ROOM

FLEXIBLE
CONNECTIONS
NATURAL SMOKE (FIRE RATED)
OUTLETS 2.5% OF
FLOOR AREA
PENETRATION
SEAL
PAVEMENT SHOP

SPRINKLER
SYSTEM

STORE BASEMENT ROOM

FIRE RATED WALLS FIRE RATED FLOORS NON-FIRE RATED WALLS

IN THE DIAGRAM

The fire rated duct system shown must be suitable for clearing smoke within the compartments and normally
rated for 1 or 2 hour stability and integrity to resist hot smoke and fire from inside (Type B). Insulation fire rating is
not required in the first compartment.

Where the basement duct rises through the shop above shown it must maintain stability, integrity and
insulation fire rating for the same period of time as the compartment through which it passes and this may be
required for the remainder of the ductwork route through the building to outside.

In some circumstances the insulation requirements may be waived or varied by the Regulatory Authority if there are
no combustible materials within 500mm of the duct, such as in the plantroom shown (BS 9999:2008 Clause
W.4).

In all areas the duct must retain at least 75% of the cross sectional area, for the same period of time as the
compartment through which it passes.

All fire rated ductwork and penetration seals must be tested to BS 476-24/ISO 6944 by a recognised NAMAS/UKAS
accredited laboratory.

Note: Final approval must always be obtained from the Local Building Control Officer/Fire Department prior to
commencement of construction.

17
 10. Dual Ventilation/Smoke Extract
Dual ventilation/smoke extract systems can operate in two different modes to provide an
economical solution for ventilation and smoke extraction.

Operates as a conventional ductwork system under normal conditions. Operates as a smoke

extract system under fire conditions. Smoke extract ductwork must retain at least 75% of its
cross sectional area, both in the fire compartment as well as adjacent compartments.

CHANGEOVER DAMPERS TO CHANGE

SYSTEM FROM SUPPLY AIR TO SMOKE
EXTRACT

PLANT ROOM

MOTORISED SMOKE/FIRE
DAMPERS

SERVICE SHAFT

ESCAPE
OFFICE CORRIDOR STORE ROOM

DUCT SUPPLY/
EXTRACT
SUITABLE FOR
CLEANING SMOKE
ESCAPE
OFFICE CORRIDOR PRINT ROOM

FIRE RATED WALLS FIRE RATED FLOORS NON-FIRE RATED WALLS

IN THE DIAGRAM

Systems that can operate in two different modes may offer economical solutions for smoke extraction. The ductwork
shown must be suitable for clearing smoke within the compartments and normally rated for 1 hour for stability
and integrity to resist hot smoke and fire from inside (Type B). Insulation fire rating is not required in the first
compartment.

Where the duct crosses the escape corridor shown it must maintain stability, integrity and insulation fire rating
for the same period of time as the compartment through which it passes and this may be required for the remainder
of the ductwork route through the building to the outside.

In some circumstances insulation requirements may be waived or varied by the Regulatory Authority if there are no
combustible materials within 500mm of the duct, such as in the plant room shown (BS 9999:2008 Ref. W.4)
But, stability and integrity must still be maintained for the relevant period of time.

In order that the 75% cross sectional free area criteria be maintained, fire rated ductwork would be used within the
service shaft requiring stability and integrity shown However, if there are combustible materials within 500mm
of the duct, insulation would still be needed.

All fire rated ductwork and penetration seals must be tested to BS 476-24/ISO 6944 by a recognised NAMAS/UKAS
accredited laboratory.

Note: Final approval must always be obtained from the Local Building Control Officer/Fire Department prior to
commencement of construction.

18
11. Pressurisation Ductwork System
Pressurisation ducts must be able to maintain an air supply to critical areas for the duration of
the fire.

Air supply must be maintained, fire dampers cannot be used. All ductwork penetrating fire
compartments must be fire rated in order to maintain compartmentation.

Pressurisation plant should be in a dedicated plant room or separated from other equipment
by a one hour fire resistant enclosure – BS 5588 part 4, clause 6.3.4.

FIRE RATED FAN

ROOF PLANT ROOM TESTED TO BS 7346

PENETRATION SEAL

FIRE RESISTING
PRESSURISATION
DUCT TYPE A

LIFT LOBBY OFFICE

NON FIRE
RATED DUCT

PROTECTED ESCAPE
LIFT LOBBY SHAFT CORRIDOR STAIRS LOBBY

FIRE RATED WALLS FIRE RATED FLOORS NON-FIRE RATED WALLS

IN THE DIAGRAM

A pressurisation system is a special form of mechanical ventilation which maintains a positive pressure in critical areas
to stop smoke from entering from adjacent areas, typically used in protected stairways, lobbies, corridors and fire
fighting shafts.

Ductwork shown is passing through a dedicated plantroom supplying air and requires a minimum rating of 1
hour for stability and integrity to resist fire from outside (Type A).

Where it passes through the office shown it must maintain stability, integrity and insulation fire rating for the
same period of time as the compartment through which it passes and this may be required for the remainder of the
ductwork route through the building to the pressurised lobbies. Ductwork within the lobby or corridor shown
need not be fire rated.

Ductwork shown is in a protected shaft constructed to Method 2 of BS 9999:2008 with no other services and in
some circumstances insulation requirements may be waived or varied by the Regulatory Authority if there are no
combustible materials or other services within 500mm of the duct (BS 9999:2008 Ref W.4).

All fire rated ductwork and penetration seals must be tested to BS 476-24/ISO 6944 by a recognised NAMAS/UKAS
accredited laboratory.

Note: Final approval must always be obtained from the Local Building Control Officer/Fire Department prior to
commencement of construction.

19
 12. High Risk Areas
Areas of high risk will require separate and independent extract systems (BS 9999:2008 Clause
33.4.2.)

Such areas would typically include: boiler rooms, solvent extracts, specialist dust extracts and
lift ventilation ducts.

ROOF PLANT ROOM

LIFT SHAFT
VENTILATION DUCT

LIFT MOTOR
ROOM

OFFICE
LIFT
SHAFT

LOADING BAY /
BOILER HOUSE OIL TANK / GAS
VENTILATION BOOSTER ROOM
DUCT

BOILER PENETRATION SEAL

HOUSE

BASEMENT STORE ROOM

FIRE RATED WALLS FIRE RATED FLOORS NON-FIRE RATED WALLS

IN THE DIAGRAM

Some ductwork systems extracting fine powders or chemical solvents are considered to have a high fire risk and are
recommended to be independent of the ventilation system extracting from the building.

The duct systems shown must all be suitable for resisting fire from inside (Type B) rated for stability and
integrity. Insulation rating is not required in the first compartment.

In all the remaining areas the duct shown must retain stability integrity and insulation fire rating for the same
period of time as the compartment through which it passes and this may be required for the remainder of the
ductwork route through the building.

In some circumstances insulation requirements may be waived by the Regulatory Authority if there are no
combustible materials within 500mm of the duct, such as in the plantroom shown (BS 9999:2008 Ref. W.4)

All fire rated ductwork and penetration seals must be tested to BS 476-24/ISO 6944 by a recognised NAMAS/UKAS
accredited laboratory.

Note: Final approval must always be obtained from the Local Building Control Officer/Fire Department prior to
commencement of construction.

20
13. Penetration Seals
Between Fire Compartments
Fire stopping must be carried out between compartments. Detailed here are two typical fire
rated ductwork stopping’s, as tested to BS 476 Part 24 (1987) and ISO 6944 (1985), with the
FLAMEBAR duct system.

Mineral Wool & Calcium Silicate Board Fire Stopping

HT MINERAL HT MINERAL
SCREW FIXINGS WOOL PACKING WOOL PACKING
SCREW FIXINGS

CALCIUM SILICATE
CALCIUM SILICATE
100mm
100mm

BOARD (30mm THICK)

BOARD (30mm THICK)
MIN
MIN

FLANGE

STIFFENER
OR FLANGE
50mm MAX
OR WITHIN WALL

FLAMEBAR GFS 1000 Fire Stopping

GFS 1000 MORTAR GFS 1000 MORTAR

STIFFENER
FLANGE OR FLANGE

GFS 1000 MORTAR

50mm MAX
OR WITHIN WALL

It is very important that the fire duct is adequately stiffened within or adjacent to the
penetration seal to prevent delaminating of the duct in a fire situation which would
compromise the integrity of the fire compartment.

21
 14. Standards
Testing FLAMEBAR BW11 fire rated ductwork has
also passed the hose stream test of ASTM -
The range of FLAMEBAR BW11 fire rated
E119 with water pressure of 207Kpa (30 psi)
ductwork has been tested by the Loss
for 21/2 minutes.
Prevention Council in accordance with BS
476 Part 24 (1987) and ISO 6944 (1985), for Impact Resistance
vertical and horizontal ductwork, with fire
FLAMEBAR BW11 tested to BS EN 1128, in
inside and outside the duct, in excess of 4
which there was no penetration, debonding,
hours stability and integrity and up to 4
cracking or other visible failure of the coating
hours insulation, for ventilation ductwork,
on impact. Therefore complying with the
smoke extract ductwork or kitchen extract
failure criteria described for particleboard in
ductwork.
the standard.
FLAMEBAR BW11 fire rated ductwork has
also been tested by the Loss Prevention Flexural Strength
Council in accordance with BS 476 Part 6 FLAMEBAR BW11 has a flexural strength of
(1989) for fire propagation, confirming that 468N/mm2.
the product can be defined as a Class ‘O’
Material in accordance with the Building Moisture Absorption
Regulations 1991. FLAMEBAR BW11 is not recommended for
continuous external exposure without
FLAMEBAR BW11 fire rated ductwork has additional protection.
also been tested by the Loss Prevention
Council in accordance with BS 476 Part 7 FLAMEBAR BW11 is suitable for occasional
(1987) for surface spread of flame in exposure to rain.
accordance with the flame spread
classification given in the standard. Durability
FLAMEBAR BW11 fire rated ductwork
FLAMEBAR BW11 fire rated ductwork has system coating inspection carried out on May
also been tested by LUL to BS6853 and 2009 at the Canary Wharf site (installed in
satisfied the fire safety code of practice 1997) and Brook Green, Hammersmith,
requirements for smoke emission and toxic London site (installed in 1995) showed no
fume emission. visual deterioration. Warrington Fire report
FLAMEBAR BW11 fire rated ductwork has no. 183681.
the USA Underwriters Laboratory UL
classification for up to 4 hours fire and
Environmental
FLAMEBAR BW11 fire rated ductwork
smoke ductwork.
complies with Leadership in Energy and
FLAMEBAR BW11 has been tested by Environmental Design (LEED) objectives to
Underwriters Laboratory in the USA to maximise the use of recycled materials and
determine compliance with NFPA 90A reduce the use of natural resources.
(Installation of Air Conditioning and
Ventilation Systems) for flame spread and Chemical Resistance
smoke development with the following FLAMEBAR BW11 has been tested in
results: standard 10% solutions of the following
acids; hydrochloric, nitric & sulphuric
Flame Spread Smoke
NFPA
Stipulation
not to exceed Development no 10% solutions of the following alkalises;
25 higher than 50 sodium hydroxide & potassium hydroxide
BW11 and the following solvents; xylene & acetone.
9.4 0.2
Results
After 10 days total immersion, all the
Test conducted in accordance with UL chemicals failed to cause a breakdown of the
standard 723 “Test for Surface Burning product structure.
Characteristics of Building Materials” (ASTM-
E84).

22
15. System Advantages
Air Leakage Pressure
The construction and sealing of FLAMEBAR As FLAMEBAR BW11 is based on a GSS duct
BW11 fire rated ductwork systems allows construction, it has the advantage of the
the ductwork to be tested up to high same friction pressure loss as for normal
pressure, if required by the clients DW144 ducting and the same calculations can
specification, which has a leakage limit be used.
of .0001 x P0.65 litres per second per square
metre of duct surface area, as laid down by Shape
the HVCA specification DW143. FLAMEBAR BW11 fire rated ductwork can be
manufactured in rectangular, flat oval or
Higher pressures and lower leakage rates circular form.
can be achieved if required by the client’s
specification. Weight
FLAMEBAR BW11 fire rated ductwork is the
Expansion lightest fire duct system available.
As all steel expands with temperature, there
will naturally be an expansion of fire Size
ductwork under fire conditions as follows: FLAMEBAR BW11 fire rated ductwork is fully
certificated for any size of ductwork in the
At 1100oC an expansion of 0.01562 mm per
vertical and horizontal plane up to 25m x 3m
mm (0.016 in per in)
(82’ x 10’) cross sectional area.
At 600oC an expansion of 0.00852 mm per
mm (0.008 in per in)
Acoustic Properties
At 430oC an expansion of 0.06106 mm per FLAMEBAR BW11 fire rated ductwork
mm (0.006 in per in) achieves a sound reduction index to BS 2750
part 3 (1980) as tabled below:
Thermal Properties
‘U’ value - thermal transmittance.
BW11 without insulation = 5.0 w/m2k Anti-Drumming
(0.88 Btu/ft2hoF) FLAMEBAR BW11 fire rated ductwork has a
BW11 with 50mm insulation = 0.833 w/m2k damping co-efficient to BS AU125 (1996) of
(0.147 Btu/ft2hoF) 19db per second decay rate.
BW11 with 100mm insulation = 0.48 w/m2k In-line Plant can be treated with FLAMEBAR
(0.08 Btu/ft2hoF) BW11, if suitably constructed.

Frequency (Hz)
Systems
63 125 250 500 1k 2k 4k 8k
BW11 10.2 11.7 16.7 21.7 27.7 32.7 37.7 43.7 dB
BW11 + 60kg/m3,
11.0 12.5 17.5 22.5 28.5 33.5 38.5 44.5 dB
50mm Insulation
BW11 + 105kg/m3,
13.4 14.9 19.9 24.9 30.9 35.9 40.9 46.9 dB
50mm Insulation

Single Source Responsibility Cleaning

1. The design of all FLAMEBAR BW11 The smooth internal finish of FLAMEBAR
systems is to a certified standard. BW11 systems enable easy cleaning of the
2. All FLAMEBAR BW11 fire rated ductwork ductwork therefore it is ideal for kitchen
is manufactured and sprayed to QA ISO extract duct installations.
9001 standard.
3. All FLAMEBAR BW11 fire rated ductwork
is installed by approved licensees.
4. A certificate of conformity is issued
following final inspection, certifying
compliance with all necessary regulations.

23
FLAMEBAR BW11 Fire Rated Ductwork Systems are protected by design right.

LICENSEE

This Application and Technical Manual has been produced by Firespray International Ltd who have a policy of
continuous Product and System improvement and reserve the right to change Methods and Specifications without notice.

FIRESPRAY INTERNATIONAL LTD FLAMEBAR HOUSE SOUTH ROAD TEMPLEFIELDS HARLOW ESSEX CM20 2AR ENGLAND
TEL: +44 1279 634 230 FAX: +44 1279 634 232 e-mail: [email protected] www.firespray.eu.com