Passive Fire Solution for Retrofitted Projects: Upgrading In-situ Plasterboard to Code

How Tech Coatings is providing better outcomes for the passive coatings market.

Shane Wyatt and the Tech Coatings team launched their first intumescent coating into New Zealand less than a year ago. They’re now aspiring to create revolutionary change in the passive fire market.

With the growth of building refurbishment, passive fire protection can throw up a number of challenges when dealing with existing lining and structure. One problem area is the treatment of lift shafts, riser shafts and stairwells, typically lined with 13mm plasterboard.

Now there is an NZ-tested coating to apply to insitu plasterboard to bring it up to passive fire code. Perfect for lift shafts, riser shafts and stairwells, FBL-100 enables buildings to meet passive fire code without time consuming and expensive removal of existing plasterboard.

Emergency stairwell.

Image supplied.

Initial research undertaken by the company unearthed a problem in the market. A significant number of buildings throughout NZ contain 13mm standard plasterboard (secured using the standard fixing system) as part of a fire resistance rated mid-floor and/or wall system. Under the current New Zealand Building Code (NZBC) these systems are inadequate for passive fire protection so an upgrade is required. Existing solutions involve either: i) installing an additional layer of plasterboard, or ii) replacing all the existing plasterboard with a fire rated system.

Both solutions are labour intensive, costly and time consuming for building owners.

The Tech Coatings product, FBL-100 is a tested solution suitable for both existing and new buildings. The halogen free, low VOC, acrylic co-polymer latex thin film intumescent coating is especially designed for interior passive fire protection. FBL-100 is a hard, durable, abrasion resistant coating that produces a smooth, white architectural finish that can then be top coated with any compatible waterborne enamel.

Plasterboard ceiling.

Image supplied.

FBL-100 is perfect for refurbishing and upgrading of passive fire protection in existing or new building stock. FBL-100 provides a 60/60/60 FRR over an existing 13mm standard plasterboard lined, timber framed wall exposed to either:

- Fire from either or both sides (two-way FRR)

- Fire from the coated side (one-way FRR), or

- 13mm standard plasterboard lined, timber midfloor/ ceiling system exposed to fire from below

FBL-100 is quick drying and easy to apply, making it time efficient and less disruptive compared to current remediation options. Sections, floors or areas can be closed off as the application takes place - ideal for high use areas such as stairwells and elevator shafts, or areas where it is difficult or impossible to remove and replace the plasterboard such as riser shafts.

Adding another layer of plasterboard or removing the existing passive fire system is no longer required. FBL-100 can be applied directly to the top of the existing system to meet the requirements of the NZBC.

Testing and Assessment

Although FBL-100 is tested in the US (through Underwriters Laboratories - UL), Tech Coatings needed to ensure the testing data they presented would be specific for use in NZ as per the current NZBC.

For Tech Coatings it was never a question of ‘if’ they would test on local products, only ‘when’ and the task of testing ‘down under’ was a significant undertaking. Initially testing was conducted at CSIRO in Australia. Shane and the team worked closely with the laboratory technicians, ensuring the product was rigorously tested using multiple set-ups and substrates.

Full scale wall test with service penetrations (PFITS).

Image supplied.

After completing all the initial test phases in Australia and achieving some great results, Tech Coatings released FBL-100 into the NZ market. They’ve continued testing to see how FBL-100 can assist with fire protection on various other substrates and configurations.

Timber penetration test (PFITS).

Image supplied.

In early 2019, Andy Bain opened NZ’s newest and most technologically advanced fire laboratory - Passive Fire Inspection & Testing Services (PFITS). Tech Coatings was invited to be part of the PFITS initial testing and certification process. This enabled Tech Coatings to bring their testing back to NZ. It was also an opportunity to support a local testing facility that shares the same values.

With testing facilities close to home and PFITS’ eagerness to test their new facilities, Tech Coatings has continued to test, including several different penetration tests, from timber (image lower left) to a full-scale wall simulation (image left). FBL-100 has continued to exceed all testing expectations.

With a primary focus on reform and regulation in the industry, Tech Coatings joined the Fire Protection Association of New Zealand (FPANZ). FPANZ, interested in establishing a Coatings Working Group, invited Shane to set up the group with the initial goal of establishing a ‘technical guidance document’ for the industry. This document is a work in progress but will provide a guideline for the specification and application of Intumescent Coating Systems (ICS) on structural steel. This document supports the progressive work FPANZ is involved in, particularly around the passive fire protection issues that exist in the industry.

Tech Coatings NZ has a clear vision on who they are and what they want to achieve. Expect to hear more on them as they make inroads into the passive fire market, as campaigners for change, and as they look to launch new products.

Company Background

Established in 2017, Tech Coatings offers passive fire protective coatings, tested in Australasia on locally sourced materials. The company’s mission - to provide high quality reliable products, accompanied by an extensive quality assurance system, making it easier to specify, and ensuring ease of compliance. For more information, visit the Tech Coatings website www.techcoatings.co.nz or find them on EBOSS.