Intumescent Coating Achieves Excellent Fire Ratings — Even on Specialist Plasterboards

Tech Coatings is supplying passive fire solutions to the Canterbury District Health Board’s seven-year remediation project at Christchurch Hospital.

As part of the CDHB’s novel passive fire approach, they chose to apply Tech Coating’s FBL-100 intumescent coating to existing substrates. The appeal of this approach arises from the fact that adding a layer of FBL-100 serves a multitude of purposes, the primary ones being the guarantee to achieve the required FRR when upgrading fire-separating elements and at the same time disposing of the requirement to rip out and replace the existing linings.

The complexity of the Christchurch Hospital project constantly calls for new, adaptable solutions that concurrently need to be provided on short notice.

Most recently, Tech Coatings was tasked to extend its application range to include a tested and endorsed passive fire solution for GIB's X-Block, which is utilised as a lead-free protective barrier for medical X-ray diagnostic rooms to shield staff and occupants against unacceptable levels of radiation.

Tech Coatings tested the addition of FBL-100 to Gib’s X-Block system at FTS Laboratory in Auckland in accordance with AS 1530.4:2014 using the following specimen:

3000 x 3000mm (2970 x 2990mm specimen) Full-Scale test constructed in accordance with NZS 3604,
On 90 x 45mm timber framing with studs at 600mm centres and nogs at 800mm centres,
Lined on the exposed side with one layer of 13mm GIB X-Block Plasterboard, installed in accordance with the GIB X-block Guide with X-Block Jointing compound and GIB Grabber Screws, then coated with 1000μm of FBL-100 coating system,
Lined on the un-exposed side and one layer of 13mm GIB Standard plasterboard, installed in accordance with the GIB Site Guide

Tech Coatings was able to provide the required FRR of -/60/60 when exposed to fire from the GIB X-Block/FBL-100 side and was therefore able to provide a fully tested and endorsed system.

Advantages of the system:

Provides required protection from X-ray radiation and necessary FRR rating
Environmentally friendly as lead free, halogen free and low VOC
Eliminates complex and costly installation procedures
Allows for a uniform appearance and architectural surface finish

IntuGuard Intumescent Coatings System

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The IntuGuard Intumescent Coatings System (ICS), is the amalgamation of FBL-100 & MediGuard.

NZ-Owned Business

FBL-100 has been tested as per NZBC C/AS2 -C/AS6 Appendix C, for interior use only, as part of a providing a 'Fire Resistance Rating' (FRR) of up to 60/60/60 on either:
- Timber (or better) framed walls exposed to fire from either or both sides (two-way FRR), or exposed to fire from the coated side (one way FRR)
- Timber framed (or better) floor/ceiling systems exposed to fire from below in residential, commercial or industrial buildings on 13mm Standard Plasterboard
FBL-100 has been tested as per NZBC C/VM2 Appendix A and can be used to prevent spread of fire on interior wall or ceiling substrates. It achieves Group 2-S on Type 1 (most reactive) as per C/VM2 A1.6, Table A2
FBL-100 can be applied over existing pre-painted surfaces
FBL-100 can be applied on new or existing substrates, subject to fixing pattern (refer to TCNZ for further instruction)
FBL-100 can be applied to structural timber works and can also be used to protect internal load bearing wood from fire, therefore reducing cross-sectional area requirements, or omitting the use of encapsulating board
For the purpose of defining the 'Level of finish' for pre-application of FBL-100
- The surface that is to be coated must be finished to minimum Level 4, (AS/NZS 2589)
For the purpose of defining the 'Level of Finish' for post-application of FBL-100
- Once FBL-100 has been applied, it achieves an indicative Level 4 for walls and ceilings, although the finish level will be as per the sample provided by the 'TCNZ Certified Applicator'
FBL-100 has been tested to be used on building materials and building practices used in projects designed and built on and after 1995
For the purpose of defining the classification of 'Interior Environments' that FBL-100 may be used in, is as per AS/NZS 2311.1 — Section 2, Table 2.1:
- FBL-100 may be used in Category C1 (Very Low) and C2 (Low) environments

Timber (or better) framed walls exposed to fire from either or both sides (two-way FRR), or exposed to fire from the coated side (one way FRR)
Timber framed (or better) floor/ceiling systems exposed to fire from below in residential, commercial or industrial buildings on 13mm Standard Plasterboard

The surface that is to be coated must be finished to minimum Level 4, (AS/NZS 2589)

Once FBL-100 has been applied, it achieves an indicative Level 4 for walls and ceilings, although the finish level will be as per the sample provided by the 'TCNZ Certified Applicator'

FBL-100 may be used in Category C1 (Very Low) and C2 (Low) environments

B2.3.1 Performance — Building elements must, with only normal maintenance, continue to satisfy the performance requirements of this code for the lesser of the specified intended life of the building, if stated, or (c) 5 years if:
- (i) The building elements (including services, linings, renewable protective coatings, and fixtures) are easy to access and replace, and
- (ii) Failure of those building elements to comply with the building code would be easily detected during normal use of the building

(i) The building elements (including services, linings, renewable protective coatings, and fixtures) are easy to access and replace, and
(ii) Failure of those building elements to comply with the building code would be easily detected during normal use of the building

FBL-100 has been tested and assessed to:
- AS 1530.4:2014 — Methods for fire tests on building materials, components and structures: Fire resistance tests for elements of construction; and
- ISO 9705:1993 — Fire Test: Full-scale room test for surface products
As per the following:
- Appendix C (normative) Test Methods of any of the NZBC – C/Acceptable Solutions (C/AS2 — C/AS6)
- Appendix A (normative): Establishing Group Numbers for lining materials of NZBC – C/Verification Method Two (C/VM2)
Therefore, is able to be used where the New Zealand Building code calls for a Fire Resistance Rating (FRR) or where a Group 2-S or better Interior Lining is needed

AS 1530.4:2014 — Methods for fire tests on building materials, components and structures: Fire resistance tests for elements of construction; and
ISO 9705:1993 — Fire Test: Full-scale room test for surface products

Appendix C (normative) Test Methods of any of the NZBC – C/Acceptable Solutions (C/AS2 — C/AS6)
Appendix A (normative): Establishing Group Numbers for lining materials of NZBC – C/Verification Method Two (C/VM2)

FBL-100 has been designed to achieve a NZBC Group Number for surface finishes as per Appendix A of NZBC C/VM2.FBL-100 has been tested and assessed to achieve a Group 2-S on Type 1 substrates or better as per Appendix A1.6 Table A2 of NZBC C/VM2

All relevant certificates, assessments and reports are available upon request.

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