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Testing, calibrating, advising
TEST REPORT
Fire resistance test in accordance with AS1530.4-2014 of various
penetration
systems in a 96mm thick fire-rated plasterboard wall system
protected by the
Thermobreak/FI-Block fire stop system.
EWFA Report No:
51713700.1
Report Sponsor:
Sekisui Pilon Pty Ltd
1-5 Parraweena Road
Taren Point NSW 2229
Test Date:
13 October 2017
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Report No. 51713700.1 Page 2 of 37
© Exova Warringtonfire Aus Pty Ltd 2018
DOCUMENT REVISION STATUS
Date Issued Issue No Description
5/01/2018 51713700.1 Initial Issue
8/01/2018 51713700.2 Amendments to item 3 product name and
typographical error.
CONTACT INFORMATION
Exova Warringtonfire Aus Pty Ltd - ABN 81 050 241 524
NATA Registered Laboratory
Unit 2, 409-411 Hammond Road Dandenong Victoria 3175
Australia
T: +61 (0)3 9767 1000
SIGNATORIES
Prepared by Reviewed by Reviewed by
Kai Loh Anthony Rosamilia Steven Halliday
GENERAL CONDITIONS OF USE
This report may only be reproduced in full without modifications
by the report sponsor only. Copies, extracts or abridgments of this
report in any form shall not be made distributed or published by
other organisations or individuals without the permission in
writing from a Director of Exova Warringtonfire Aus Pty Ltd.
https://www.google.com/maps/place/409-411+Hammond+Rd,+Dandenong+South+VIC+3175,+Australia/@-38.0220036,145.2051256,17z/data=!3m1!4b1!4m2!3m1!1s0x6ad613ca6a1f8c59:0x4ad2505864219abahttps://www.google.com/maps/place/409-411+Hammond+Rd,+Dandenong+South+VIC+3175,+Australia/@-38.0220036,145.2051256,17z/data=!3m1!4b1!4m2!3m1!1s0x6ad613ca6a1f8c59:0x4ad2505864219abahttps://www.google.com/maps/place/409-411+Hammond+Rd,+Dandenong+South+VIC+3175,+Australia/@-38.0220036,145.2051256,17z/data=!3m1!4b1!4m2!3m1!1s0x6ad613ca6a1f8c59:0x4ad2505864219aba
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Report No. 51713700.1 Page 3 of 37
© Exova Warringtonfire Aus Pty Ltd 2018
CONTENTS
1 Construction Details 4 Test Assembly 4 Test Specimens 4
Assembly and Installation Methods 4 Orientation 4
2 Schedule of Components 5
3 Test Procedure 13 Statement of compliance 13 Variations to
test method 13 Pre-test conditioning 13 Sampling / Specimen
Selection 13 Ambient Temperature 13 Test Duration 13
Instrumentation and Equipment 13
4 Test Measurements 13 Furnace Temperature and Pressure
Measurements 13 Specimen Temperatures 13 Observations 13
5 Test Results 14
6 Application of Test Results 15 Test Limitations 15 Variations
from the Tested Specimens 15 Uncertainty of measurement 15
APPENDIX 1 DRAWINGS OF TEST ASSEMBLY 16
APPENDIX 2 TEST OBSERVATIONS 19
APPENDIX 3 DIRECT FIELD OF APPLICATION 21 General 21 A 3.1
Separating elements 21 A 3.2 Metal pipes 21 A 3.3 Electrical and
communication cables 22 A 3.4 Plastics pipes 22 A 3.5 Control
joints 23 A 3.6
APPENDIX 4 INSTRUMENTATION POSITIONS 24
APPENDIX 5 TEST DATA 28 Furnace Temperature 28 A 5.1 Furnace
Pressure 28 A 5.2 Specimen Temperatures 29 A 5.3
APPENDIX 6 PHOTOGRAPHS 36
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1 CONSTRUCTION DETAILS
TEST ASSEMBLY
The test assembly comprised a nominal 1200mm wide × 1200mm high
× 96mm thick fire-rated plasterboard wall system with various
penetrations.
TEST SPECIMENS
The test specimen comprised of various services protected by the
Thermobreak/ Fi-Block fire-stop system. The test assembly is
summarised in the table below.
The full description of the specimen is provided in Figures A1.1
to A1.4 and the ‘Schedule of Components’ in Section 2.
Service Item Fire Stop
Primary Insulation (
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2 SCHEDULE OF COMPONENTS
Item Description
1
Separating Element
Product CSR Fyrchek RE Plasterboard / 64mm Rondo Studs /
Rockwool
Size 96mm thick wall incorporating one layer of 16mm thick FR
plasterboard sheet on either side of the 64mm 0.55 BMT deep Rondo
steel wall frame.
PB Density Nominal: 786kg/m3
Specification
The 90 minute rated wall system was 1200mm wide × 1200mm
high.
The perimeter studs, top and bottom tracks were fixed to the
concrete blockwork using Ø6.5mm x 75mm screw Anchor Hex Head
fasteners. Noggings were installed above and below 758mm from the
bottom.
The steel wall frame was lined with Rockwool.
Plasterboard sheets were fixed to the metal framing using 6g x
32mm Bugle Head Needle Point Coarse Thread Zinc-Yellow screws at
nominal 300mm centres.
Penetration Protection
Fire Stops
2
Product Name Fi-Block ST30
Size 50mm wide x 2.12mm thick x 250mm/330mm/500mm long
(measured)
Density 2887 kg/m3 (measured)
Installation
Three (3) pairs of strips were installed over the primary
insulation, 20mm thick Thermobreak Tubes (item 3). The Fi-Block
ST30 were secured together with reinforced foil tape (item 9), with
overlap such that the strips hugged the insulation tightly. Sealant
(item 8) was applied between the Fi-Block ST30 strips and the
separating element (item 1).
See Appendix 1 for more details.
Insulation
3
Product Name 20mm – 25mm thick Thermobreak Tubes (Primary
Insulation)
Size
Outer Diameter Inner Diameter Wall Thickness
65mm 25mm 20mm
78mm 38mm 20mm
101mm 51mm 25mm
114mm 64mm 25mm
Installation
Installed as the primary insulation around the services except
for the paircoil. The insulation was installed through the core
hole and extended 400mm either side of the separating element (item
1).
See Appendix 1 for more details.
4
Product Name Thermobreak Thermacoil (Primary and Tertiary
Insulation)
Size
Outer Diameter Inner Diameter Wall Thickness
50mm 9.5mm 20mm
55.24mm 15.9mm 20mm
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Item Description
Installation
Installed as the primary and tertiary insulation on the
paircoil. The primary insulation was installed through the core
hole and extended 400mm either side of the separating element (item
1), while the tertiary insulation was installed beyond the 400mm
distance from the separating element (item 1)
See Appendix 1 for more details.
5
Product Name Thermobreak Solar Wrap (Secondary Insulation)
Size 150mm / 200mm wide x 8mm thick
Density 78.1 kg/m3 (measured)
Installation
Two (2) layers installed as the secondary insulation to the
services. The secondary insulation was installed over the primary
insulation to 400mm from either side of the separating element
(item 1). The 150mm wide wrap was installed on the unexposed side
between the separating element (item 1) and the first pipe ferrules
(item 7) secured together with reinforced foil tape (item 9) and
cable ties (item 10).
The 200mm wide wrap was installed on both the unexposed and
exposed side. On the unexposed side the 200mm wide wrap was
installed between the pipe ferrules and secured with reinforced
foil tape only. On the exposed side, two sets of the 200mm wide
wrap were installed back to back up to 400mm from the separating
element and was secured together with reinforced foil tape (item 9)
and cable ties (item 10).
Sealant (item 8) was applied in the annular gap before the wraps
closest to the separating element were installed. Additional
sealant (item 8) was then applied after the installation.
See Appendix 1 for more details.
6
Product Name 40mm thick Thermobreak Tubes (Tertiary
Insulation)
Size
Outer Diameter Inner Diameter Wall Thickness
105mm 25mm 40mm
118mm 38mm 40mm
131mm 51mm 40mm
144mm 64mm 40mm
Installation
One layer installed as the tertiary insulation to the services
except the paircoil. The tertiary insulation was installed beyond
the 400mm distance from either side of the separating element (item
1) and was secured to the services using only the reinforced foil
tape (item 9).
See Appendix 1 for more details.
Pipe Ferrules
7
Product Name Thermaloc Ferrules
Size
Outer Diameter Inner Diameter Wall Thickness
51mm 9.5mm 20mm
57mm 15.9mm 20mm
110mm 25mm 40mm
115mm 38mm 40mm
131mm 51mm 40mm
144mm 64mm 40mm
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Item Description
Installation
Two (2) sets installed at 200mm and 500mm from the separating
element (item 1) and secured using only the reinforced foil tape
(item 9).
See Appendix 1 for more details.
Sealant
8
Product Name Hilti CP606
Installation
First layer applied in the annular gap of the separating element
(item 1) to the depth of the plasterboard. Second layer then
applied between the Solar Wrap (item 5) and the separating element
interface.
See Appendix 1 for more details.
Fixings/ Adhesives
9
Product Name Reinforced Foil Tape
Installation Applied around all circumferential joins of the
insulations of the services ensuring that no exposed foam or
blanket is showing.
10
Product Name 7.9mm wide Steel Cable Ties
Installation
Installed over the final layer of insulations starting nominally
50mm from each end and the middle, and nominally 30mm from each end
for a narrower insulation at nominally 50mm centre spacing to the
full length of the services on both the exposed and unexposed
side.
SERVICE A
11
Pipe System
Product name DN25 Type B Copper Pipe
Pipe Dimensions
Outside Diameter (OD) 25.4 mm (measured) × 1.2 mm thick
(measured) pipe that protruded nominally 500 mm on the exposed side
and on the unexposed side. The pipe was capped on the exposed side
using cooper end caps with KAO wool inside.
Pipe Support The pipe was supported on the unexposed side with
unistrut and pipe clamps at approximately 150 mm and 400 mm from
the unexposed face.
Core Hole Size Ø92 mm
Primary Penetration Protection
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Item Description
Installation
The copper pipe was protected by Thermobreak/Fi-Block fire-stop
system which consisted and were installed in the following
order:
1) One piece of a nominally 896mm long by 20mm thick Thermobreak
Tube (item 3) with an internal diameter of 25mm was installed over
the pipe. The Thermobreak Tube was installed through the core hole
and extended 400mm either side of the separating element (item
1).
2) Three (3) strips of Fi-Block ST30 (item 2) were installed at
mid-length of the pipe through the core hole over the Thermobreak
Tube (item 3); reinforced foil tape was used to secure the strips.
Plenty of overlap was provided ensuring the strips don’t become
unstuck.
3) One nominally 100mm long by 40mm thick Thermobreak Tube (item
6) with an internal diameter of 25mm was installed at both the
exposed and unexposed ends (400mm from the separating element (item
1)) of the pipe.
4) Two (2) pipe ferrules (item 7) with an internal diameter of
25mm were installed at 150mm and 400mm from the separating element
on the unexposed side over the pipe itself with the 20mm thick
Thermobreak Tube (item 3) being removed at the locations of the
pipe ferrules.
5) The 200mm wide Thermobreak Solar Wrap (item 5) was then
installed on the unexposed side between the two pipe ferrules (item
7).
6) Internal sealant (item 8) was then applied in the annular
gaps of the core hole (between the Fi-Block ST30 strips (item 2)
and the separating element (item 1)) to full depth of the
plasterboard (item 1).
7) Once the internal sealant had formed a skin, the remaining
Thermobreak Solar Wraps (item 5) were installed on both the exposed
and unexposed side.
8) A layer of sealant (item 8) was then applied between the
Thermobreak Solar Wraps (item 5) and interface of the separating
element (item 1).
The system was secured with reinforced foil tape (item 9) and
cable ties (item 10).
See Figure A1.3 in Appendix 1 for more details.
SERVICE B
12
Service Bundle
Pair Coil
DN10 + DN18 Type B Copper Pipes
Outside Diameter (OD) 9.5 mm (measured) × 0.9 mm thick
(measured) and Outside Diameter (OD) 15.9 mm (measured) × 1.0 mm
thick (measured) pipe that protruded nominally 500 mm on the
exposed side and on the unexposed side. The pipe was capped on the
exposed side using cap end.
Cables
Two 2C (2.5mm2) + E (2.5mm
2) TPS Cables
Protruded nominally on the 500mm exposed and 500mm on the
unexposed side
Service Support
The pipe was supported on the unexposed side with unistrut and
pipe clamps at approximately 150 mm and 400mm from the unexposed
face.
Core Hole Size Ø80 mm + Ø86 mm (overlapping cores)
Primary Penetration Protection
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Item Description
Installation
The service bundle was protected by Thermobreak/Fi-Block
fire-stop system which consisted and were installed in the
following order:
1) One piece per copper pipe of a nominally 896mm long by 20mm
thick Thermobreak Thermacoil (item 4) with an internal diameter of
9.5mm and 15.9mm was installed over the two copper pipes. The
Thermobreak Thermacoil was installed through the core hole and
extended full length either side of the separating element (item
1).
2) Three (3) strips of Fi-Block ST30 (item 2) were installed at
mid-length of each pipe individually through the core hole over the
Thermobreak Thermacoil (item 4); reinforced foil tape was used to
secure the strips. Plenty of overlap was provided ensuring the
strips don’t become unstuck.
3) Two (2) pipe ferrules (item 7) per copper pipe with an
internal diameter of 9.5mm and 15.9mm were installed at 150mm and
400mm from the separating element on the unexposed side over the
pipe itself with the 20mm thick Thermobreak Thermacoil (item 4)
being removed at the locations of the pipe ferrules.
4) The TPS cables were then installed in between the two copper
pipes with the 200mm wide Thermobreak Solar Wrap (item 6) was
installed on the unexposed side between the two pipe ferrules (item
7) wrapping the two copper pipes and TPS cables together.
5) Internal sealant (item 8) was then applied in the annular
gaps of the core hole (between the Fi-Block ST30 strips (item 2)
and the separating element (item 1)) to full depth of the
plasterboard.
6) Once the internal sealant had formed a skin, the remaining
Thermobreak Solar Wraps (item 5) were installed on both the exposed
and unexposed side.
7) A layer of sealant (item 8) was then applied between the
Thermobreak Solar Wraps (item 5) and interface of the separating
element (item 1).
The system was secured with reinforced foil tape (item 9) and
cable ties (item 10).
See Figure A1.2 in Appendix 1 for more details.
SERVICE C
13
Pipe System
Product Name DN50 Type B Copper Pipe
Pipe Dimensions
Outside Diameter (OD) 50.8 mm (measured) × 1.2 mm thick
(measured) pipe that protruded nominally 500 mm on the exposed side
and on the unexposed side. The pipe was capped on the exposed side
using cap end.
Pipe Support The pipe was supported on the unexposed side with
unistrut and pipe clamps at approximately 150 mm and 400mm from the
unexposed face.
Core Hole Size Ø127 mm
Primary Penetration Protection
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Report No. 51713700.1 Page 10 of 37
© Exova Warringtonfire Aus Pty Ltd 2018
Item Description
Installation
The copper pipe was protected by Thermobreak/Fi-Block fire-stop
system which consisted and were installed in the following
order:
1) One piece of a nominally 896mm long by 25mm thick Thermobreak
Tube (item 3) with an internal diameter of 51mm was installed over
the pipe. The Thermobreak Tube was installed through the core hole
and extended 400mm either side of the separating element (item
1).
2) Three (3) strips of Fi-Block ST30 (item 2) were installed at
mid-length of the pipe through the core hole over the Thermobreak
Tube (item 3); reinforced foil tape was used to secure the strips.
Plenty of overlap was provided ensuring the strips don’t become
unstuck.
3) One nominally 100mm long by 40mm thick Thermobreak Tube (item
6) with an internal diameter of 51mm was installed at both the
exposed and unexposed ends (400mm from the separating element (item
1)) of the pipe.
4) Two (2) pipe ferrules (item 7) with an internal diameter of
51mm were installed at 150mm and 400mm from the separating element
on the unexposed side over the pipe itself with the 25mm thick
Thermobreak Tube (item 3) being removed at the locations of the
pipe ferrules.
5) The 200mm wide Thermobreak Solar Wrap (item 5) was then
installed on the unexposed side between the two pipe ferrules (item
7).
6) Internal sealant (item 8) was then applied in the annular
gaps of the core hole (between the Fi-Block ST30 strips (item 2)
and the separating element (item 1)) to full depth of the
plasterboard.
7) Once the internal sealant had formed a skin, the remaining
Thermobreak Solar Wraps (item 5) were installed on both the exposed
and unexposed side.
8) A layer of sealant (item 8) was then applied between the
Thermobreak Solar Wraps (item 5) and interface of the separating
element (item 1).
The system was secured with reinforced foil tape (item 9) and
cable ties (item 10).
See Figure A1.3 in Appendix 1 for more details.
SERVICE D
14
Pipe System
Product Name DN40 Type B Copper Pipe
Pipe Dimensions
Outside Diameter (OD) 38.1 mm (measured) × 1.2 mm thick
(measured) pipe that protruded nominally 500 mm on the exposed side
and on the unexposed side. The pipe was capped on the exposed side
using cap end.
Pipe Support The pipe was supported on the unexposed side with
unistrut and pipe clamps at approximately 150 mm and 400mm from the
unexposed face.
Core Hole Size Ø111 mm
Primary Penetration Protection
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Item Description
Installation
The copper pipe was protected by Thermobreak/Fi-Block fire-stop
system which consisted and were installed in the following
order:
1) One piece of a nominally 896mm long by 20mm thick Thermobreak
Tube (item 3) with an internal diameter of 38mm was installed over
the pipe. The Thermobreak Tube was installed through the core hole
and extended 400mm either side of the separating element (item
1).
2) Three (3) strips of Fi-Block ST30 (item 2) were installed at
mid-length of the pipe through the core hole over the Thermobreak
Tube (item 3); reinforced foil tape was used to secure the strips.
Plenty of overlap was provided ensuring the strips don’t become
unstuck.
3) One nominally 100mm long by 40mm thick Thermobreak Tube (item
6) with an internal diameter of 38mm was installed at both the
exposed and unexposed ends (400mm from the separating element (item
1)) of the pipe.
4) Two (2) pipe ferrules (item 7) with an internal diameter of
38mm were installed at 150mm and 400mm from the separating element
on the unexposed side over the pipe itself with the 20mm thick
Thermobreak Tube (item 3) being removed at the locations of the
pipe ferrules.
5) The 200mm wide Thermobreak Solar Wrap (item 5) was then
installed on the unexposed side between the two pipe ferrules (item
7).
6) Internal sealant (item 8) was then applied in the annular
gaps of the core hole (between the Fi-Block ST30 strips (item 2)
and the separating element (item 1)) to full depth of the
plasterboard.
7) Once the internal sealant had formed a skin, the remaining
Thermobreak Solar Wraps (item 5) were installed on both the exposed
and unexposed side.
8) A layer of sealant (item 8) was then applied between the
Thermobreak Solar Wraps (item 5) and interface of the separating
element (item 1).
The system was secured with reinforced foil tape (item 9) and
cable ties (item 10).
See Figure A1.2 in Appendix 1 for more details
SERVICE E
15
Pipe System
Product Name DN65 Type B Copper Pipe
Pipe Dimensions
Outside Diameter (OD) 63.5 mm (measured) × 1.2 mm thick
(measured) pipe that protruded nominally 500 mm on the exposed side
and on the unexposed side. The pipe was capped on the exposed side
using cap end.
Pipe Support The pipe was supported on the unexposed side with
unistrut and pipe clamps at approximately 150 mm and 400mm from the
unexposed face.
Core hole Diameter
Ø140 mm
Primary Penetration Protection
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Report No. 51713700.1 Page 12 of 37
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Item Description
Installation
The copper pipe was protected by Thermobreak/Fi-Block fire-stop
system which consisted and were installed in the following
order:
1) One piece of a nominally 896mm long by 25mm thick Thermobreak
Tube (item 3) with an internal diameter of 64mm was installed over
the pipe. The Thermobreak Tube was installed through the core hole
and extended 400mm either side of the separating element (item
1).
2) Three (3) strips of Fi-Block ST30 (item 2) were installed at
mid-length of the pipe through the core hole over the Thermobreak
Tube (item 3); reinforced foil tape was used to secure the strips.
Plenty of overlap was provided ensuring the strips don’t become
unstuck.
3) One nominally 100mm long by 40mm thick Thermobreak Tube (item
6) with an internal diameter of 64mm was installed at both the
exposed and unexposed ends (400mm from the separating element (item
1)) of the pipe.
4) Two (2) pipe ferrules (item 7) with an internal diameter of
64mm were installed at 150mm and 400mm from the separating element
on the unexposed side over the pipe itself with the 20mm thick
Thermobreak Tube (item 3) being removed at the locations of the
pipe ferrules.
5) The 200mm wide Thermobreak Solar Wrap (item 5) was then
installed on the unexposed side between the two pipe ferrules (item
7).
6) Internal sealant (item 8) was then applied in the annular
gaps of the core hole (between the Fi-Block ST30 strips (item 2)
and the separating element (item 1)) to full depth of the
plasterboard..
7) Once the internal sealant had formed a skin, the remaining
Thermobreak Solar Wraps (item 5) were installed on both the exposed
and unexposed side.
8) A layer of sealant (item 8) was then applied between the
Thermobreak Solar Wraps (item 4) and interface of the separating
element (item 1).
The system was secured with reinforced foil tape (item 9) and
cable ties (item 10).
See Figure A1.3 in Appendix 1 for more details.
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3 TEST PROCEDURE
STATEMENT OF COMPLIANCE
The test was performed in accordance with the requirements of
AS1530.4-2014 Sections 2 & 10 subject to the variations
below.
VARIATIONS TO TEST METHOD
None
PRE-TEST CONDITIONING
The construction of the specimen was finished on the 6 October
2017 and was tested on 13 October 2017. During this period the test
specimen was subject to normal laboratory temperatures and relative
humidity conditions.
SAMPLING / SPECIMEN SELECTION
The laboratory was not involved in the sampling or selection of
the test specimen for the fire resistance test.
AMBIENT TEMPERATURE
The ambient temperature at the start of the test was 20°C and
varied between 20°C and 22°C during the test.
TEST DURATION
The test duration was 121 minutes.
INSTRUMENTATION AND EQUIPMENT
The instrumentation was provided in accordance with
AS1530.4-2014 and as detailed below:
The furnace temperature was measured by 4-off mineral insulated
metal sheathed Type K thermocouples with wire diameters not greater
than 1mm and overall diameter of 3mm with the measuring junction
insulated from the sheath. The thermocouples protruded a minimum of
25mm from steel supporting tubes.
The unexposed side specimen temperatures were measured by Type K
thermocouples with wire diameters less than 0.5mm soldered to 12mm
diameter × 0.2mm thick copper discs covered by 30mm × 30mm × 2.0 mm
inorganic insulating pads. The thermocouple positions are described
in Table A4.1, and are shown on Figure A4.1 in Appendix 4.
A roving thermocouple was available to measure temperatures at
positions that appeared hotter than the positions monitored by the
fixed thermocouples.
The furnace pressure was measured at the centre of lowest
service.
Cotton pads were available during the test to assess the
performance under the criteria for integrity.
4 TEST MEASUREMENTS
FURNACE TEMPERATURE AND PRESSURE MEASUREMENTS
Furnace temperature and pressure data are provided in Figure
A5.1 and Table A5.1 in Appendix 5.
SPECIMEN TEMPERATURES
Specimen temperature data is provided in A 5.3 and Table A5.2 in
Appendix 5.
OBSERVATIONS
A table that includes observations of the significant behaviour
of the specimen and details of the occurrence of the various
performance criteria specified in AS1530.4-2014 is provided in
Appendix 2. Photographs of the specimen are included in Appendix
6.
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5 TEST RESULTS
The specimens listed below achieved the following performance
when tested in accordance with AS1530.4-2014, Section 2 & 10
subject to the variations listed in Section 3.
Service Criteria Result
A
Structural Adequacy Not applicable
Integrity No failure at 121 minutes
Insulation Failure at 93 minutes
FRL -/120/90
B
Structural Adequacy Not applicable
Integrity No failure at 121 minutes
Insulation Failure at 81 minutes
FRL -/120/60
C
Structural Adequacy Not applicable
Integrity No failure at 121 minutes
Insulation Failure at 70 minutes
FRL -/120/60
D
Structural Adequacy Not applicable
Integrity No failure at 121 minutes
Insulation Failure at 94 minutes
FRL -/120/90
E
Structural Adequacy Not applicable
Integrity No failure at 121 minutes
Insulation Failure at 71 minutes
FRL -/120/60
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6 APPLICATION OF TEST RESULTS
TEST LIMITATIONS
The results of this fire test may be used to directly assess
fire hazard, but it should be recognized that a single test method
will not provide a full assessment of fire hazard under all fire
conditions. The results only relate to the behaviour of the
specimen of the element of the construction under the particular
conditions of the test; they are not intended to be the sole
criteria for assessing the potential fire performance of the
element in use nor do they necessarily reflect the actual behaviour
in fires.
VARIATIONS FROM THE TESTED SPECIMENS
This report details the methods of construction, the test
conditions and the results obtained when the specific element of
construction described herein was tested following the general
procedure outlined in AS1530.4. Any significant variation with
respect to size, constructional details, loads, stresses, edge or
end conditions, other than those allowed under the field of direct
application in the relevant test method, is not addressed by this
report. It is recommended that any proposed variation to the tested
configuration other than as permitted under the field of direct
application specified in APPENDIX 3 should be referred to the test
sponsor in the first instance to obtain appropriate documentary
evidence of compliance from Exova Warringtonfire Aus Pty Ltd or
another Registered Testing Authority.
UNCERTAINTY OF MEASUREMENT
Because of the nature of fire resistance testing and the
consequent difficulty in quantifying the uncertainty of measurement
of fire resistance, it is not possible to provide a stated degree
of accuracy of the result.
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APPENDIX 1 DRAWINGS OF TEST ASSEMBLY
Figure A1.1: Plan of Test Specimen
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Figure A1.2: Cross-Section A-A
Figure A1.3: Cross-Section B-B
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Figure A1.4: Cross-Section C-C
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APPENDIX 2 TEST OBSERVATIONS
The following include observations of the significant behaviour
of the specimen.
Time Observations
min sec
Service A
00 00 Fire resistance test commenced and the ambient temperature
was approximately 20°C.
30 00 Specimen continued to maintain integrity and insulation in
accordance with AS1530.4-2014.
60 00 Specimen continued to maintain integrity and insulation in
accordance with AS1530.4-2014.
90 00 Specimen continued to maintain integrity and insulation in
accordance with AS1530.4-2014.
93 24 TC 013 recorded 200°C. Failure of insulation in accordance
with AS1530.4-2014 clause 2.13.3(b), where the maximum temperature
of the thermocouple exceeded the initial temperature by more than
180°C.
120 00 Specimen continued to maintain integrity in accordance
with AS1530.4-2014.
121 00 Fire resistance test ended.
Service B
00 00 Fire resistance test commenced and the ambient temperature
was approximately 20°C.
01 25 Smoke emitting from cable near thermocouples.
25 00 Smoke emission has decreased significantly.
30 00 Specimen continued to maintain integrity and insulation in
accordance with AS1530.4-2014.
42 33 Sealant beginning to crack on the underside of the
penetration.
60 00 Specimen continued to maintain integrity in accordance
with AS1530.4-2014.
81 10 TC 023 recorded 201°C. Failure of insulation in accordance
with AS1530.4-2014 clause 2.13.3(b), where the maximum temperature
of the thermocouple exceeded the initial temperature by more than
180°C.
90 00 Specimen continued to maintain integrity in accordance
with AS1530.4-2014.
120 00 Specimen continued to maintain integrity in accordance
with AS1530.4-2014.
121 00 Fire resistance test ended.
Service C
00 00 Fire resistance test commenced and the ambient temperature
was approximately 20°C.
30 00 Specimen continued to maintain integrity and insulation in
accordance with AS1530.4-2014.
41 12 Sealant beginning to crack on the underside of the
penetration.
60 00 Specimen continued to maintain integrity and insulation in
accordance with AS1530.4-2014.
64 00 Sealant crack growing larger and beginning to expand.
70 30 TC 033 recorded 199°C. Failure of insulation in accordance
with AS1530.4-2014 clause 2.13.3(b), where the maximum temperature
of the thermocouple exceeded the initial temperature by more than
180°C.
90 00 Specimen continued to maintain integrity in accordance
with AS1530.4-2014.
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Time Observations
min sec
120 00 Specimen continued to maintain integrity in accordance
with AS1530.4-2014.
121 00 Fire resistance test ended.
Service D
00 00 Fire resistance test commenced and the ambient temperature
was approximately 20°C.
30 00 Specimen continued to maintain integrity and insulation in
accordance with AS1530.4-2014.
41 12 The mastic seal is beginning to crack on the upper side of
the penetration.
60 00 Specimen continued to maintain integrity and insulation in
accordance with AS1530.4-2014.
78 00 Sealant expanding and cracking.
90 00 Specimen continued to maintain integrity and insulation in
accordance with AS1530.4-2014.
94 25 TC 043 recorded 200°C. Failure of insulation in accordance
with AS1530.4-2014 clause 2.13.3(b), where the maximum temperature
of the thermocouple exceeded the initial temperature by more than
180°C.
120 00 Specimen continued to maintain integrity in accordance
with AS1530.4-2014.
121 00 Fire resistance test ended.
Service E
00 00 Fire resistance test commenced and the ambient temperature
was approximately 20°C.
30 00 Specimen continued to maintain integrity and insulation in
accordance with AS1530.4-2014.
38 57 Slight smoke emission from the lower side of the pipe
insulation.
41 12 The mastic seal is beginning to crack on the upper side of
the penetration.
58 00 Foam insulation beginning to melt.
60 00 Specimen continued to maintain integrity and insulation in
accordance with AS1530.4-2014.
64 00 Sealant crack growing larger and beginning to expand.
71 40 TC 054 recorded 199°C. Failure of insulation in accordance
with AS1530.4-2014 clause 2.13.3(b), where the maximum temperature
of the thermocouple exceeded the initial temperature by more than
180°C.
90 00 Specimen continued to maintain integrity in accordance
with AS1530.4-2014.
110 00 The melting insulation is dripping down the wall.
120 00 Specimen continued to maintain integrity in accordance
with AS1530.4-2014.
121 00 Fire resistance test ended.
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Report No. 51713700.1 Page 21 of 37
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APPENDIX 3 DIRECT FIELD OF APPLICATION
GENERAL A 3.1
AS1530.4-2014 indicates that the results of the fire test
contained in the test report are directly applicable without
reference to the testing authority to similar constructions where
one or more of the changes have been made:
SEPARATING ELEMENTS A 3.2
Results obtained for sealing systems in various types of masonry
and concrete construction may be applied as follows:
a) For elements manufactured from similar types of concrete or
masonry, the results of the prototype test may be applied to
materials of density within ±15% of the tested specimen. For
greater variations, the opinion of a registered testing authority
shall be obtained.
b) Test results obtained in conjunction with hollow concrete
blocks may be used in a solid concrete element of the same overall
thickness. The reverse does not apply.
c) Results obtained from framed wall systems may be applied to
the performance of a system in concrete, masonry or solid gypsum
blocks of greater or equal thickness to that of the tested
prototype. The reverse does not apply.
d) Results obtained from framed wall systems may be applied to
similar walls having studs of the same material with sizes greater
than the tested prototype.
e) Results obtained from a prototype test may be applied to
framed wall systems of similar construction but having thicker
facings of the same material applied to the studs.
METAL PIPES A 3.3
A 3.3.1 Sealing systems tested using standard configurations
The results may be applied to brass pipes of the same
composition up to maximum outside diameter of 101.6 mm (normally
70/30 arsenical brass) and to copper and ferrous metal pipes having
wall thicknesses greater than or equal to those listed in Table
10.12.3.1, provided the same penetration sealing system was used
for the above penetrations in the same type of separating element
and all the specimens achieved the required FRL.
NOTE: For information on standard configurations, see Appendix
F.
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A 3.3.2 Sealing systems tested not using standard
configurations
Results obtained with a penetration sealing system protecting
the opening around copper or brass pipes may be applied to pipes of
the same material and to ferrous metal pipes having outside
diameters not greater than the tested diameter, and wall
thicknesses not less than the tested thickness.
NOTE: For information on standard configurations for metal
pipes, see Appendix F.
A 3.3.3 Shape and size of openings for penetration seals
For mineral-fibre, cast and gun-applied mastic seals, results
obtained in openings with a smooth surface texture may be applied
to openings having a rough surface texture.
A 3.3.4 Insulated (lagged) metal pipes
Where fire test data on the insulation system are not available,
penetration sealing systems that have been subjected to the
standard test with uninsulated metal pipes may be used, provided
the appropriate requirements of Clause A 3.3.2 are satisfied and
the following procedures are followed:
a) If the insulation is non-combustible or is manufactured
solely from mineral fibre, it shall be cut away where the service
penetrates the separating element, and the opening shall be
fire-stopped in accordance with the tested method.
b) If the insulation is combustible, it shall be cut away for
1000 mm either side of the separating element (provided the pipe
did not vent hot gases during the fire resistance test), and the
pipe shall be fire-stopped in accordance with the tested method. A
non-combustible lagging may be placed over the bare pipe. If
venting occurs during the fire-resistance test at a time less than
the required FRL, a fire test shall be carried out to evaluate the
insulated pipe system.
A 3.3.5 Alternative pipe materials
If an element is penetrated by—
a) a pipe other than brass, copper or ferrous alloys;
b) a pipe of cross-section other than circular; or
c) a pipe outside the field of application specified in this
Standard for the standard test configuration,
then the results obtained from a single tested system may be
applied to these pipes provided the—
i. melting point of the material is equal to or greater than the
tested specimen;
ii. surface area to mass ratio of a cross-section of the pipe is
equal to or less than the tested specimen; and
iii. thermal conductivity is equal to or less than the tested
specimen diffusivity of the material.
ELECTRICAL AND COMMUNICATION CABLES A 3.4
Where standard configurations are used for electrical and
communication cables, the results of tests may be applied to all
PVC and XLPE insulated and PVC sheathed power and communication
cables with copper conductors, provided the results are for the
same penetration sealing system in the same separating element and
all of the specimens achieved the designated FRL or greater.
NOTE: For information on recommended standard configurations for
electrical and communication cables, see Appendix D.
PLASTICS PIPES A 3.5
A 3.5.1 General
In addition to the requirements of Clause A 3.2, test results
may be directly applied to masonry and concrete elements thicker
than the tested prototype when installed in accordance with Figure
10.12.5.1 (AS 1530.4).
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Results obtained from a particular test shall not be applied to
plastics pipes of different diameters, wall thicknesses or material
types.
Results obtained from tests on penetrations through vertical
separating elements shall not be used to assess performance in
horizontal elements, and vice versa.
As penetration seals for plastics pipes are dependent for
activation upon exposure to fire conditions, they shall always be
installed with the same orientation and fire exposure as was
established in the fire-resistance test.
A 3.5.2 Services not perpendicular to the fire separation
Penetrations not perpendicular to the plane of the element are
acceptable, provided the fire-stopping system has similar exposure
and dimensions to the tested prototype.
CONTROL JOINTS A 3.6
The following variations are permitted:
a) Results obtained from single test on a butt joints may be
applied to contoured joints, provided the joints have—
i. equal width and equal or greater depth of sealant; and
ii. equal or greater thickness of fire-separating element.
NOTE: Examples of butt and contoured control joints are shown in
Figure 10.12.6.
b) Facings may be applied to the surface of the fire-stopping
system.
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APPENDIX 4 INSTRUMENTATION POSITIONS
Service A Service A
Service B Service B
Service C Service C
021
022 023
024
036
033
035 037
038
012 014
013
011
017
018
025
027
026
031
032
015
016
029
028
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Service D Service D
Service E Service E
Figure A4.1: Unexposed surface thermocouple locations
044
042
046
043
047 048
051
053
052
054
057 058
045
041
055
056
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Table A4.1: Thermocouple Locations
Service T/C No. Description
A
011 On the wall, 25mm above the service.
012 On the wall, 25mm west of the service.
013 On top of the pipe, 25mm away from the wall.
014 On the west side of the pipe, 25mm away from the wall.
015 On top of the pipe, 25mm away from the interface of the two
types of insulation.
016 On the west side of the pipe, 25mm away from the interface
of the two types of insulation.
017 On top of the pipe, 25mm away from the interface of the two
types of insulation.
018 On the west side of the pipe, 25mm away from the interface
of the two types of insulation.
B
021 On the wall, 25mm above the service.
022 On the wall, 25mm west of the service.
023 On top of the service, 25mm away from the wall.
024 On the west side of the service, 25mm away from the
wall.
025 On top of the service, 25mm away from the insulation
step.
026 On the west side of the service, 25mm away from the
insulation step.
027 On top of the service on the insulation step.
028 On top of the bigger pipe, 25mm away from the interface of
the two types of insulation.
029 On the west side of the smaller pipe, 25mm away from the
interface of the two types of insulation.
C
031 On the wall, 25mm above the service.
032 On the wall, 25mm west of the service.
033 On top of the pipe, 25mm away from the wall.
034 On the west side of the pipe, 25mm away from the wall.
035 On top of the pipe, 25mm away from the interface of the two
types of insulation.
036 On the west side of the pipe, 25mm away from the interface
of the two types of insulation.
037 On top of the pipe, 25mm away from the interface of the two
types of insulation.
038 On the west side of the pipe, 25mm away from the interface
of the two types of insulation.
D
041 On the wall, 25mm above the service.
042 On the wall, 25mm east of the service.
043 On top of the pipe, 25mm away from the wall.
044 On the east side of the pipe, 25mm away from the wall.
045 On top of the pipe, 25mm away from the interface of the two
types of insulation.
046 On the east side of the pipe, 25mm away from the interface
of the two types of insulation.
047 On top of the pipe, 25mm away from the interface of the two
types of insulation.
048 On the east side of the pipe, 25mm away from the interface
of the two types of insulation.
E 051 On the wall, 25mm above the service.
052 On the wall, 25mm east of the service.
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Service T/C No. Description
053 On top of the pipe, 25mm away from the wall.
054 On the east side of the pipe, 25mm away from the wall.
055 On top of the pipe, 25mm away from the interface of the two
types of insulation.
056 On the east side of the pipe, 25mm away from the interface
of the two types of insulation.
057 On top of the pipe, 25mm away from the interface of the two
types of insulation.
058 On the east side of the pipe, 25mm away from the interface
of the two types of insulation.
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APPENDIX 5 TEST DATA
FURNACE TEMPERATURE A 5.1
Figure A5.1: Furnace Temperatures vs. Time
FURNACE PRESSURE A 5.2
The furnace pressure was measured at mid-height of the lowest
penetration.
Table A5.1: Pressure
Time
(minutes)
Pressure (Pa)
Avg.
Time
(minutes)
Pressure (Pa)
Avg.
Time
(minutes)
Pressure (Pa)
Avg.
5-10 16 45-50 15 85-90 16
10-15 17 50-55 15 90-95 15
15-20 15 55-60 15 95-100 15
20-25 16 60-65 15 100-105 16
25-30 15 65-70 15 105-110 15
30-35 15 70-75 15 110-115 15
35-40 15 75-80 15 115-120 15
40-45 15 80-85 15
0
200
400
600
800
1000
1200
0 15 30 45 60 75 90 105 120
Tem
pera
ture
(°C
)
Time (Minutes)
AS 1530.4 Mean Furn Max Furn Min Furn
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SPECIMEN TEMPERATURES A 5.3
Figure A5.2: Service A. Temperature vs. time
Figure A5.3: Service A. Temperature vs. time
0
50
100
150
200
250
300
0 15 30 45 60 75 90 105 120
Tem
pera
ture
(°C
)
Time (minutes)
011 012 013 014
0
20
40
60
80
100
120
0 15 30 45 60 75 90 105 120
Tem
pera
ture
(°C
)
Time (minutes)
015 016 017 018
-
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Figure A5.4: Service B. Temperature vs. Time
Figure A5.5: Service B. Temperatures vs. Time
0
50
100
150
200
250
300
0 15 30 45 60 75 90 105 120
Tem
pera
ture
(°C
)
Time (minutes)
021 022 023 024
0
20
40
60
80
100
120
140
160
0 15 30 45 60 75 90 105 120
Tem
pera
ture
(°C
)
Time (minutes)
025 026 027 028 029
-
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Figure A5.6: Service C. Temperature vs. Time
Figure A5.7: Service C. Temperature vs. Time
0
50
100
150
200
250
300
350
0 15 30 45 60 75 90 105 120
Tem
pera
ture
(°C
)
Time (minutes)
031 032 033 034
0
20
40
60
80
100
120
140
160
180
200
0 15 30 45 60 75 90 105 120
Tem
pera
ture
(°C
)
Time (minutes)
035 036 037 038
-
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Figure A5.8: Service D. Temperature vs. Time
Figure A5.9: Service D. Temperature vs. Time
0
50
100
150
200
250
300
0 15 30 45 60 75 90 105 120
Tem
pera
ture
(°C
)
Time (minutes)
041 042 043 044
0
20
40
60
80
100
120
140
160
180
0 15 30 45 60 75 90 105 120
Tem
pera
ture
(°C
)
Time (minutes)
045 046 047 048
-
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Figure A5.10: Service E. Temperature vs. Time
.
Figure A5.11: Service E. Temperature vs. Time
0
50
100
150
200
250
300
350
0 15 30 45 60 75 90 105 120
Tem
pera
ture
(°C
)
Time (minutes)
051 052 053 054
0
50
100
150
200
250
0 15 30 45 60 75 90 105 120
Tem
pera
ture
(°C
)
Time (minutes)
055 056 057 058
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Table A5.2: Test Specimen Temperatures
Service T/C No.
Description2
Temp (°C) at t (minutes) Limit1
(Mins) t=0 t=30 t=60 t=90 t=120
A
011 On the wall, 25mm above the service. 20 71 83 102 199
120
012 On the wall, 25mm west of the service. 20 71 91 110 222
110
013 On top of the pipe, 25mm away from the wall.
20 61 92 191 237 100
014 On the west side of the pipe, 25mm away from the wall.
19 78 94 176 231 93
015 On top of the pipe, 25mm away from the interface of the two
types of insulation.
20 49 73 80 110 -
016 On the west side of the pipe, 25mm away from the interface
of the two types of insulation.
19 66 74 81 109 -
017 On top of the pipe, 25mm away from the interface of the two
types of insulation.
20 23 30 35 40 -
018 On the west side of the pipe, 25mm away from the interface
of the two types of insulation.
20 23 29 33 39 -
B
021 On the wall, 25mm above the service. 20 73 90 109 220
116
022 On the wall, 25mm west of the service. 20 74 93 118 250
104
023 On top of the service, 25mm away from the wall.
20 81 99 215 254 81
024 On the west side of the service, 25mm away from the
wall.
20 68 71 139 235 103
025 On top of the service, 25mm away from the insulation
step.
20 68 77 92 110 -
026 On the west side of the service, 25mm away from the
insulation step.
20 63 63 76 101 -
027 On top of the service on the insulation step.
19 81 112 131 151 -
028 On top of the bigger pipe, 25mm away from the interface of
the two types of insulation.
20 33 39 42 49 -
029 On the west side of the smaller pipe, 25mm away from the
interface of the two types of insulation.
20 29 33 36 42 -
C
031 On the wall, 25mm above the service. 20 75 90 110 234
112
032 On the wall, 25mm west of the service. 19 79 94 125 243
101
033 On top of the pipe, 25mm away from the wall.
19 70 152 240 290 70
034 On the west side of the pipe, 25mm away from the wall.
19 65 120 176 219 102
035 On top of the pipe, 25mm away from the interface of the two
types of insulation.
19 64 104 137 187 -
036 On the west side of the pipe, 25mm away from the interface
of the two types of insulation.
19 57 88 98 111 -
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Notes 1 Limit time is the time to the nearest whole minute,
rounded down to the nearest minute, at which the temperature
recorded by the thermocouple does not rise by more than 180K above
the initial temperature.
2 Refer to Appendix 4 for locations of thermocouples as only a
generic description is included in the table.
3 No insulation failure prior to thermocouple failure.
# Thermocouple failure
*
Service failure
‘-’ Under limit column indicates the temperature limit was not
exceeded during the test period or up until the time of integrity
failure if a failure occurred.
037 On top of the pipe, 25mm away from the interface of the two
types of insulation.
20 26 38 45 54 -
038 On the west side of the pipe, 25mm away from the interface
of the two types of insulation.
20 25 34 39 47 -
D
041 On the wall, 25mm above the service. 20 73 90 109 214
116
042 On the wall, 25mm east of the service. 20 72 88 109 212
117
043 On top of the pipe, 25mm away from the wall.
20 63 105 190 248 94
044 On the east side of the pipe, 25mm away from the wall.
19 64 96 176 225 104
045 On top of the pipe, 25mm away from the interface of the two
types of insulation.
20 50 76 100 158 -
046 On the east side of the pipe, 25mm away from the interface
of the two types of insulation.
19 51 76 90 112 -
047 On top of the pipe, 25mm away from the interface of the two
types of insulation.
20 24 33 37 42 -
048 On the east side of the pipe, 25mm away from the interface
of the two types of insulation.
20 23 32 37 40 -
E
051 On the wall, 25mm above the service. 19 79 105 243 296
82
052 On the wall, 25mm east of the service. 19 81 109 233 274
82
053 On top of the pipe, 25mm away from the wall.
19 68 152 206 235 87
054 On the east side of the pipe, 25mm away from the wall.
19 67 166 229 256 71
055 On top of the pipe, 25mm away from the interface of the two
types of insulation.
19 66 106 145 214 113
056 On the east side of the pipe, 25mm away from the interface
of the two types of insulation.
19 68 96 115 169 -
057 On top of the pipe, 25mm away from the interface of the two
types of insulation.
20 28 41 50 61 -
058 On the east side of the pipe, 25mm away from the interface
of the two types of insulation.
19 26 39 46 53 -
-
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APPENDIX 6 PHOTOGRAPHS
Figure A6.1: Unexposed face of specimen before commencement of
the fire-resistance test
Figure A6.2: Exposed face of specimen before commencement of the
fire-resistance test
East West
West East
A B
C E
D
H
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Figure A6.3: Unexposed face of specimen at the end of the
test.
Figure A6.4: Exposed face of specimen at the end of the
test.
West East
East West