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Nowadays there are intumescent coatings available for diverse applications. There is no established assessment of their protection performance besides the standard time-temperature curve, but natural fire scenarios often play an important role. A reliable straightforward performance-based assessment is presented. The effective thermal conductivity per thickness is calculated based on intermediate-scale fire tests. The optimum thermal insulation, the time to reach it, and the time until contingent failure of the coating are used for an assessment independent of the heating curve. The procedure was conducted on four different commercially intumescent coatings for steel construction, one solvent-based, one waterborne, one epoxy-based, and a bandage impregnated with a waterborne coating. The performance was studied under four different but similar shaped heating curves with different maximum temperatures (standard time-temperature curve, hydrocarbon curve and two self-designed curves with reduced temperature). The thermal protection performance is crucially affected by the residue morphology. Therefore, a comprehensive morphology analysis, including micro-computed tomography and scanning electron microscopy, was conducted on small-scale residues (7.5 x 7.5 cm2). Two different types of inner structures and the residue surface after different heat exposures were discussed in terms of their influence on thermal protection performance.
For intumescent coatings durability is an important aspect. Due to ageing, which is caused by climatic conditions, the thermal protection performance of intumescent coatings can be reduced during the working life. The national German and the European procedures to assess the durability of intumescent coatings presume a working life of 10 years. For a longer period, additional investigations are required. However, the European assessment procedure does not provide specific information how to prove a durability of more than 10 years. In addition to this formal reason, also from a scientifical position, it is necessary to investigate the degradation of intumescent coatings in detail to propose a corresponding test concept for a durability of more than 10 years.
The presentation summarises the existing knowledge about the degradation behaviour and ageing of intumescent coatings. Furthermore, the results of different approaches from a recently conducted research project are presented. Starting from a water-based and an epoxy-based guide formulation, in a first approach a degradation of the intumescent coating was carried out directly during the production process, i.e. by reducing the concentration of functionally relevant chemical components. In another approach, the duration of the short-term weathering tests was significantly extended, i.e. by multiple repetition of the artificial weathering. The thermal protection performance of the intumescent coating was assessed by fire tests and tests with electrical heating source. In addition, small-scale tests were carried out to determine the thermal material properties of the intumescent coating and thermo-analytical methods were applied to characterise the degradation. Derived from this knowledge, possibilities to test and assess a working life for a period of more than 10 years are proposed.
Intumescent coatings are used in civil engineering to improve the fire resistance of steel constructions. Due to the thin coating thickness and the profile-following application, the architectural appearance of the steel structure can be preserved. EN 13381-8 provides regulations to determine the contribution to the fire resistance of intumescent coatings applied to steel beams and columns. The scope of this standard excludes tension members and steel members with solid sections. For products that have already been successfully tested and assessed on beams and columns, EN 13381-10 offers the possibility based on unloaded fire tests to extend the scope of application of intumescent coatings to tension bars with solid sections. This approach contradicts the national safety level in Germany, where mechanically loaded testing is mandatory. Therefore, a new part of the test standard series EN 13381 is currently developed to enable the application of intumescent coatings on steel tension bars with solid section based on mechanically loaded fire tests. BAM has already carried out numerous fire tests on loaded steel tension members with intumescent coatings. Currently, in the BAM research project FIRESTEMIC, the influence of the steel bar orientation and the profile type on the thermal performance of intumescent coatings are investigated. Both questions concerning the thermal protection ability of intumescent coatings were analysed based on three different test sets, which were carried out in the tension furnace (Fig. 1a). The fire exposure corresponds to the standard temperature-time curve according to EN 1363-1.
This paper summarises the main findings from the fire tests conducted in the FIRESTEMIC project. The results serve as an experimental background for the proposal of the new standard. Regarding the bar orientation, a new test setup was developed and proposed for the new standard. The two tested commercial water-based intumescent coatings with applied dry film thickness from 1.5 mm to 2.5 mm showed only a slight dependence on the bar orientation. In terms of the steel profile type, circular and rectangular solid sections with identical section factor and applied dry film thickness were tested. It was observed that the circular solid bars with diameter 30 mm heat up faster compared to the solid rectangular bars with dimension 30×30 mm (Fig. 1b). Also at larger steel bars, i.e. diameter 40 mm and dimension 40×40 mm, the same trend occurred. Thus, it is recommended for the new test standard to allow a transfer of the test results from circular to rectangular solid sections. In addition, the paper will describe and explain the test and assessment procedure proposed for the newly developed standard.
The potentialities of a thin layer of steel-fiber reinforced self-compacting concrete (SFRSCC) for the flexural strengthening of handmade brick structural elements are investigated. For this purpose, an experimental program was carried out covering the relevant phenomena that can influence the effectiveness of this technique. The SFRSCC has a post-cracking residual tensile strength capable of improving the flexural stiffness, flexural resistance and ductility of prototypes representatives of ancient handmade brick based structures that fail in bending. To appraise the flexural strengthening effectiveness of this technique, straight beams composed of handmade bricks, low-strength mortar (LSM) and SFRSCC were tested. The obtained results have shown that this technique can increase significantly the flexural stiffness and resistance, and the ductility performance of this type of structures. The strengthening effectiveness depends on the post-cracking residual strength of the SFRSCC, its layer thickness and on the possibility of replacing part of the LSM by SFRSCC. Based on the experimental results for the characterization of the intervening materials, and adopting a cross section layer model capable of predicting the moment-curvature relationship for the distinct types of cross sections of this structural system, the maximum load registered in the tested prototypes was predicted with good accuracy.
In civil engineering, steel tension members are normally used for bracings, suspensions and underbracing systems. Typically, slim circular solid sections (CSS) are used for such tension members. However, sufficient knowledge about the performance of reactive fire protection systems (RFPS) applied to solid steel tension members has so far been missing. The application of RFPS on such members was not covered by national German approvals (abZ) as well as European technical assessments (ETA) and therefore only possible by approvals in individual case by the building authority. This paper describes the world’s first scientifically investigated fire tests of RFPS applied to steel tension members with CSS. The influence of various parameters such as profile geometry, dry film thickness of the RFPS, level of the load utilization as well as member orientation was tested. In addition, the foaming and cracking behaviour and thermal protection of the RFPS used are investigated and failure mechanisms are identified. To measure the steel temperature of the tension member without weakening the cross-section a special method for the application of thermocouples was developed. The fire tests show that an application of RFPS on steel tension members with solid section is generally possible. However, due to the slim cross-sections and the missing possibility of load distribution within the tension member, high requirements are placed particularly on the effectiveness and reliability of the RFPS. In particular, the testing of mechanically loaded tension members is essential, since the necessary three-dimensional foaming results in the highest stress level for the RFPS. The findings obtained from the performed fire tests are of general nature. Recommendations for the testing and assessment of RFPS applied to steel tension members with solid section are briefly described in this paper and explained in detail in [1] and [2]. Based on this research, the German building authority (DIBt) has defined national approval guidelines for the testing and the assessment of RFPS applied to tension members with solid section. Since November 2015, a general building approval for a RFPS is available in Germany.
Purpose – The purpose of this paper is to investigate the performance of intumescent coating on tension rod systems and their components. Steel tension rod systems consist of tension rods, fork end connectors and associated intersection or gusset plates. In case of fire, beside the tension rods themselves, the connection parts require appropriate fire protection. Intumescent fire protection coatings prevent a rapid heating of the steel and help secure the structural load-carrying capacity. Because the connection components of tension rod systems feature surface curvature and a complex geometry, high demand is placed on the intumescence and thermal protection performance of the coatings.
Design/methodology/approach – In this paper, experimental studies were carried out for steel tension rod systems with intumescent coating. The examined aspects include the foaming and cracking behaviour, the influence of different dry film thicknesses, the heating rate of the steel connecting parts in comparison to the tension rods, and the mounting orientation of the tension rods together with their fork end connectors.
Findings – The results show that a decrease in surface curvature and/or an increase inmass concentration of the steel components leads to a lower heating rate of the steel. Moreover, the performance of the intumescent coating on tension rod systems is influenced by themounting orientation of the steel components.
Originality/value – The findings based on fire tests contribute to a better understanding of the intumescent coating performance on connection components of tension rod systems. This subject has not been extensively studied yet.
Intumescent coatings are commonly used in civil engineering to improve the fire resistance of steel constructions. Especially in the case of tension bars, where mostly circular or rectangular solid sections are used, intumescent coatings offer an efficient measure to improve the fire resistance taking advantage of profile-following application and low coating thickness requirements. Thus, the architectural appearance of slender profiles can be preserved. The paper describes real-scale mechanically loaded and unloaded fire tests of circular and rectangular solid steel tension bars with intumescent coating. The aim of these tests is to investigate the influence of the different profile types as well as different bar orientations on the performance of intumescent coatings. The results are used to specify a normative test and assessment procedure to be implemented in a new European standard for determining the contribution of intumescent coatings to the fire resistance of circular or rectangular bars used as tension members.
Im Bauwesen werden für Zugglieder häufig Kreisvollprofile mit relativ kleinen Durchmessern eingesetzt. Diese Bauteile bestehen in der Regel aus gezogenem, kaltverformtem Blankstahl. Aufgrund des Herstellungsverfahrens kommt es zu einer Veränderung der Materialeigenschaften des Stahls. Für Blankstahl sind in der Norm [1] keine temperaturabhängigen Materialkennwerte angegeben. An der BAM Bundesanstalt für Materialforschung und -prüfung wurden im Rahmen eines Forschungsvorhabens [2] die mechanischen Hochtemperatureigenschaften von Stahlzuggliedern aus kaltverformtem Blankstahl der Festigkeitsklasse S355 untersucht. Als Ausgangsmaterial wurde ein Kreisvollprofil mit einem Durchmesser von 20 mm verwendet. Für den Blankstahl wurden die chemische Zusammensetzung, der Elastizitätsmodul, die Spannungs-Dehnungs-Kennlinien sowie der Wärmeausdehnungskoeffizient bestimmt. Ziel der Untersuchungen war es herauszufinden, welche materialspezifischen Besonderheiten kaltverformter Blankstahl unter Brandeinwirkung gegenüber anderen Stählen besitzt und inwieweit sich die in der Norm [1] für warmgewalzten Baustahl angegebenen Werte auf Blankstahl übertragen lassen. Die Ergebnisse der Materialuntersuchungen werden zudem für die numerische Nachrechnung von Brandversuchen an Stahlzuggliedern mit reaktiver Brandschutzbeschichtung verwendet.--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Mechanical properties of cold drawn steel S355 at elevated temperatures used for tension rods. In construction, circular solid steel rods with relatively small diameter are often used for tensile elements. These elements are usually made of cold drawn steel. As a result of the manufacturing process, the material properties of the steel are changed. In the standard [1], no information regarding the temperature-dependant material properties of cold drawn steel are given. At BAM Federal Institute for Materials Research and Testing, a research project [2] was conducted to investigate the mechanical properties at elevated temperatures of tension elements made of cold drawn steel type S355. In the experiments, the tensile specimens were produced from a circular solid profile with a diameter of 20 mm. Within the research project, the chemical composition, the modulus of elasticity, the stress-strain-relationships and the thermal expansion coefficient were determined. The aim of this investigation was to identify the specific material characteristics of cold drawn steel under fire exposure. Furthermore, a comparison between cold drawn steel and the commonly used in construction hot-rolled steel was done, in order to clarify whether the material properties of hot rolled steel that are given in the standard [1] can be also used for cold drawn steel. The results of the material tests are used as input values for a numerical simulation of fire tests on tension elements with reactive fire protection systems.
The application of intumescent coatings for fire protection of steel constructions is increasing.
Thanks to the relative thin thickness of the coatings, the typical visual appearance of the
structures can be preserved. In Germany, the applicability of the systems is regulated by the
national as well as European technical approvals. According to the approvals, the application
on steel members in tension is only allowed with limitations. Especially, the application on
solid steel rods in tension is currently not covered. The paper will explain the actual state of
the art of the application of reactive fire protection systems applied to steel structures.
Physical and technical background information will be provided. After that, the latest
scientific results of an on-going research project funded by the German National Institute of
Building Technology (DIBt) and conducted by the Federal Institute for Materials Research
and Testing (BAM) will be described.