FRL 240/240/240 Concrete Protection - Intubatt by FIREFLY

Protecting Concrete Structures
TBA Firefly™ Intubatt® Concrete Protection DTS Tested Systems for FRL240/240/240
Patent Pending

DTS System FRL240/240/240 tested in accordance with AS1530.4-2014, and assessed in accordance with AS4072.1-2005, Warringtonfire Report No: FAS210074 RIR. This is a report from an accredited testing laboratory that meets Specification A2.3, Section 2(c) of NCC2016 Amendment 1 (including prior versions), and Schedule 5, Section 2(c) of NCC2019 (including Amendment 1) for the determination of an FRL.

Current potential issues for some building stock in Australia:

• Concrete flat slab is less than 200mm thick.
• Alternate solution (FES) which states that the concrete slab achieves an FRP90/90/90 or FRP120/120/120 when determined in accordance with AS3600.

I believe that this may be a serious non-compliance issue, due to the fact that Table 5.5.2(A) is sometimes overlooked in some fire-engineered solutions. This means that an FRP90/90/90 or FRP120/120/120 cannot be determined in accordance with AS3600 if the floor slab is less than 200mm thick. Therefore the only route to compliance is via a DTS Tested System FRL.

Retrofit Solution

Install one layer of FIREFLY™ Intubatt® to the underside of the slab to achieve a DTS FRL240/240/240. The same applies for where the slab may be 200mm thick and designed for a building which originally only required an FRP90/90/90 or FRP120/120/120, or FRL90/90/90 or FRL120/120/120 which has since had a change of use and the FRP or FRL needs to be higher.

For Retrofit & New Build

Benefits of the FIREFLY™ Intubatt® concrete slab DTS Tested System:

• Equivalent concrete thickness (ε) for concrete slab. One layer of 50mm thick TBA Firefly™ Intubatt® is equivalent to 144.9mm thick of concrete @ 4 hours.
• 100mm thick of concrete is approximately 240kg/m² (144.9mm thick = 347.76kg/m²).
• 1 layer of 50mm thick FIREFLY™ Intubatt® is approximately 9kg/m².
• Potential weight reduction of 338kg/m².
• The structural steel/concrete vertical support between each floor level won't have to be as strong as they have less of a load to carry.
• Using 100mm thick concrete plus 50mm of FIREFLY™ Intubatt® (total 150mm), the floors are 100mm thinner, meaning that a high-rise could be designed so that it ends up with an extra floor level than that of a building designed with 250mm thick concrete slab of the same height (our system gives an extra 1000mm per 10 levels, 4m per 40 levels, etc).
• Concrete Carbon Footprint Reduction: The manufacture of cement produces about 0.9 pounds of CO2 for every pound of cement. Since cement is only a fraction of the constituents in concrete, manufacturing a cubic yard of concrete (about 3900 lbs) is responsible for emitting about 400 lbs of CO2 (source: The Portland Cement Association).

Test Image: 2400kgs point loaded on top of the test slab.

Post Test: Being removed from the furnace after being subjected to over 4 hours of exposure.

Installation Instructions

Step 1

Either run a bead of TBA Firefly™ Intumastic around the perimeter of the TBA Firefly™ Intubatt®, nominally 50mm in from the edge, then a cross from corners to corners, or directly onto the ceiling instead.

Step 2

Paint all green edges of the TBA Firefly™ Intubatt® with TBA Firefly™ Intumastic Brush Grade.

Step 3

Secure the TBA Firefly™ Intubatt® using M6.5 x 100mm long hex head masonry screws and 30mm OD x 1.5mm thick, steel penny washers. Installed @ 50mm from each corner and 50mm from the edge. 6 x fixings per full 1200mm x 600mm sheet. 4 x fixings per 600mm x 600mm or smaller.

Step 4

The TBA Firefly™ Intubatt® must be installed in a staggered brick type pattern. If any green can be seen on the joints, paint over with TBA Firefly™ Intumastic Brush Grade. The fixings and washers do NOT require painting over.

TBA Firefly™ Products

TBA Firefly™ Intubatt®.

TBA Firefly™ Intumastic.

If you're a structural engineer, fire engineer, architect, designer, builder, or building certifier/surveyor, please feel free to contact our office to obtain a copy of the Warringtonfire Compliance Report: FAS210074 RIR.