Introduction

In 1986, Fire Protection Limited began a research programme to develop an entirely new
fire resistant ductwork system.
This programme, which is continuous has resulted in the FLAMEBAR B.W.11 Fire
Resistant Ductwork System being manufactured and supplied worldwide.
As a result of continued growth, Firespray International Limited was formed to carry out
the ongoing research and development programme and also to market FLAMEBAR
products on a global basis. Fire Protection Limited now markets and installs the system
in the United Kingdom.
This Technical Manual has been produced for everyone associated with the design and
installation of fire resistant ductwork systems and illustrates how to satisfy the
requirements of the regulatory bodies. It also clearly emphasises our own commitment to
fire safety.

FLAMEBAR B.W.11 FIRE RESISTANT DUCTWORK

SYSTEMS SATISFY ANY REQUIREMENT
FOR FIRE RATED DUCTWORK FOR VENTILATION,
KITCHEN OR SMOKE EXTRACT APPLICATIONS.
2

Contents
1

Testing requirements - BS 476 Part 24 (1987) and ISO 6944 (1985) Definitions

Page 4

Fire Resistant Ductwork - When and Why

Page 6

2.1

Regulations & Codes in the United Kingdom

FLAMEBAR B.W.11 Fire Resistant Ductwork - Analysis and Performance

Page 8
Page 9

3.1

FLAMEBAR B.W.11 - Single Source Responsibility - Certificate of Conformity

Page 9

3.2

FLAMEBAR B.W.11 - Flexibility in Design

Page 9

3.3

FLAMEBAR B.W.11 - Construction of FLAMEBAR B.W.11 Fire Duct

Page 10

3.4

FLAMEBAR B.W.11 - System Integrity - Ancillary Components

Page 11

3.5

FLAMEBAR B.W.11 - Panel Construction

Page 12

3.6

FLAMEBAR B.W.11 - To BS 7346 Insulation Temperatures

Page 14

3.7

FLAMEBAR B.W.11 - Air Temperatures at Various Distances from Duct

Page 15

3.8

FLAMEBAR B.W.11 - Guide to Fire Protection of Ductwork

Page 16

3.9

FLAMEBAR B.W.11 - Fire Resistance Criteria

Page 18

3.10 FLAMEBAR B.W.11 - Supports and Hangers

Page 18

3.11 FLAMEBAR B.W.11 - Construction Standards

Page 20

Penetration Seals Between Fire Compartments

Page 21

Pro Forma Specification Example

Page 21

Standards

Page 22

FLAMEBAR B.W.11 Fire Resistant Ductwork - System Advantages

Page 23

1. Testing Requirements
British Standard 476 Part 24 (1987)
and ISO 6944 (1985)
BS 476 Part 24 (1987) Fire Tests on building materials and structures.
Part 24. Method for determination of the fire resistance of ventilation ducts
ISO 6944 (1985) Fire resistance tests - Ventilation ducts
The purpose of BS 476 Part 24 (1987) and ISO 6944 (1985) is to measure the
ability of a ductwork system to resist the spread of fire from one fire compartment to
another without the aid of fire dampers. It should be noted that the test relates to a
complete ductwork installation and therefore joints, supports and the fire stopping through
the furnace wall all form an integral part of the test.

ISO 834 : 1975 (E) Fire Resistance Test

Standard Time - Temperature Curve
1200
1100
1000

Temperature OC

900
800
700
600
500
400
300
Furnace Temperature Curve
as Specified in BS 476 Part 24
(1987) & ISO 6944 (1985)

200
100
0
0

20

40

60

80

100

120

140

160

180

200

220

240

Time (Minutes)

Giving temperature rise as a function of time for all BS 476 Part 24 (1987) & ISO 6944
(1985) Fire Tests.

Requirements of British Standard 476

Part 24 (1987) and ISO 6944 (1985)
The fire resistance of Ventilation Ductwork
shall, according to the Standard, be
expressed in Minutes of duration of heating
until failure occurs, according to one or
more of the following criteria.
1. Stability.
2. Insulation.
3. Integrity.

Insulation
Insulation failure shall be deemed to have
occurred when the temperature rises above
ambient temperature on the external face of
the duct outside the area in which the fire
is present, and exceeds either
1. 140 OC as an average value, or
2. 180 OC as a maximum value.

Criteria of Failure
Stability
Stability failure shall be deemed to have
occurred when the Duct specimen collapses
inside or outside the area in which there is
a fire in such a manner that the duct no
longer fulfils its intended function.

Integrity
The presence and the formation of holes or
other openings in the Duct in the room
adjacent to the fire (or through the fire
stopping at the dividing wall) through
which flames or hot gasses can pass, shall
constitute Integrity failure.

Definitions of Types A & B Fire Exposure

The testing standard differentiates between types of fire exposure; two classifications
apply as details below.
Compartment
with Fire
Outbreak

Adjacent Compartment
T1

Temperature
Sensor

Fire Outside
-Duct Type A
Duct Resists
Penetration of
Fire from
Outside

Ventilation or Smoke Extract Opening

- No Fire Penetration from Inside Duct

Adjacent Compartment
T2

Temperature
Sensor

Compartment with Fire Outbreak

Fire Inside
-Duct Type B
Duct Resists Penetration of Fire from Inside

Fire Penetrates
into Duct through
Ventilator or Smoke
Extract Opening

2. Fire Resistant
Ductwork
When and Why
One of the most important factors taken into consideration when designing and
constructing a building is effective compartmentation to limit fire spread throughout the
building. Under normal circumstances compartmentation is maintained by fire dampers
within ductwork systems. However under certain circumstances fire dampers should not
be used and the ductwork itself must provide the same levels of fire resistance as that
afforded by the compartment wall or floor.

Ductwork systems which do not normally contain fire dampers are as follows:
1: Smoke Extract Ducts.

3: Pressurisation Ducts.

2: Car Park Extract Ducts.

4: Kitchen Extract Ducts.

In general terms, any ductwork system that is intended to

operate or has special use under a fire condition and cannot
therefore utilise fire dampers will require a fire rating.
Ventilation systems and applications which have special or operational effect under fire
conditions are as follows:
Mechanical Ventilation System
Mechanical ventilation systems are used to
extract air from a building and to supply
replacement fresh or airconditioned air. The
necessary fans and conditioning
equipment are generally located in separate
plant rooms, often in a basement or on the
roof. The distribution of the air involves
ductwork which may be very large, extend
through the building, penetrate
compartment walls and/or floors and may
have openings in every space through
which it passes.

Without suitable fire precautions, therefore,

ventilation ductwork can provide a route by
which fire, smoke and toxic gases are
enabled to spread rapidly through a building.

Smoke Extraction Systems

Smoke extraction is the evacuation of
products of combustion, such as smoke and
toxic gases from a building, which could
otherwise reduce visibility and impair human
functions. Smoke extraction facilitates the
escape of the building occupants and assists
firefighters in locating the seat of the fire and
extinguishing it.
In situations where smoke clearance by
natural ventilation through windows or other
openings may be difficult e.g. in large or
deep basements or in high rise buildings
without opening windows, ductwork is
required to convey the smoke to a suitable
outlet from the building. In cases where the
natural buoyancy of the combustion products

is not adequate to ensure the required smoke

extraction rate through the ductwork, fan
assisted systems are used. It may also be
necessary to install duct air inlets as part of
the smoke extraction scheme, in order to
provide the replacement air.
If the ductwork incorporated in a smoke
extraction system is wholly contained within
the fire compartment, it must be capable of
resisting the anticipated temperatures
generated during the development of a fire BS
476 Part 24 (1987) and ISO 6944 (1985)
also requires duct which is intended for
smoke extract should retain at least 75% of
its cross sectional area within the fire
compartment. If the ductwork penetrates the
fire resisting barrier, it must also be capable
of providing the same period of fire
resistance.
Dual Ventilation/Smoke Extraction Systems
These serve as a conventional ventilation
system under normal conditions, but are
converted to provide smoke extraction in the
event of fire, thus providing an economical
dual solution.
Car Park Extraction Systems
Car parks which require mechanical
ventilation must have separate and
independent extraction systems, because of
the polluted nature of the extracted air. Due to
the fire risk associated with car parks these
systems should be treated as smoke extract
systems and therefore maintain a minimum of
75% cross sectional area under fire
conditions in accordance with BS 476 Part
24 (1987) and ISO 6944 (1985). Fire
dampers should not be installed in extract
ductwork serving car parks.
Pressurisation Systems
Pressurisation is a method of restricting the
penetration of smoke into certain critical areas
of a building, by maintaining the air at higher
pressures than those in adjacent areas. It
applies particularly to protected stairways,
lobbies, corridors and fire fighting shafts
serving deep basements, as smoke within

these areas would inhibit escape.

A pressurisation system is a special form of
mechanical ventilation system. The air supply
creating the pressurisation must be
maintained for the duration of a fire, fire
dampers cannot be used with the ductwork to
prevent the spread of fire. Any ductwork
penetrating fire resisting barriers should
therefore be fire resistant.
Kitchen Extraction Systems
Non-domestic kitchens are required to have
separate and independent extraction systems,
because of the polluted nature of the extracted
air. Fire dampers should not be installed in
extraction ductwork serving kitchens, any
ductwork penetrating fire resisting barriers
should be fire resistant.
Kitchen extract ductwork presents a particular
hazard as combustible deposits such as
grease are likely to accumulate on internal
surfaces. A fire in an adjacent compartment
through which the ductwork passes could
therefore lead to ignition of these deposits
which may continue through the ductwork
system, possibly prejudicing the safety of the
kitchen occupants. For this reason
consideration should be given to the
insulation performance of kitchen extract
ducts.
Finally, Where possible, access doors, for
cleaning, at distances not exceeding 3m are
recommended.
Escape Corridors and Lobbies
It is a requirement of the Building
Regulations, as defined in BS 5588 Part 9,
Clause 9.2, that any duct crossing an escape
corridor or lobby must be fire rated for
stability, integrity and insulation, for the same
period of time as the compartment through
which it passes. It should be noted that at
least one fire damper will be required if either
side of the escape corridor is constructed with
non-fire rated ductwork.

2.1. Regulations & Codes

in the United Kingdom
Statutory Instruments
England & Wales - Building & the Building Regulations 1991
Statutory Instrument. No 2768
Scotland - Building & the Building Standards (Scotland Regulations) 1990
Statutory Instrument. No 2179 Section 187
Northern Ireland - Building Regulations (Northern Ireland) 1994
Statutory Instrument. No 243
Insurance Requirements
(Association of British Insurers & Lloyds)

Support
Documents

Advisory
Guides

British Standards Institution

(BSI)
Fire Tests
International Organisation for
Standardisation (ISO)

British Standard
Codes

Approved Document B
(England & Wales)
Fire Safety
B1 Means of Escape
B2 Internal Fire Spread
(Linings)
B3 Internal Fire Spread
(Structures)
External Fire Spread
B5 Access & Facilities for
the Fire Services

Technical Standard
(Scotland)
Part D
Structural Fire Precautions
Part E
Means of Escape form Fire

Technical Booklet E
(Northern Ireland)
Fire Safety

BS 5588 Part 9 (1989)

Fire Precautions in the
Design of Construction
of Buildings. Part9.
Code of Practice for
Ventilation & Air
Conditioning Ductwork

BS 476 Part 24 (1987)

Fire Tests on Building
Materials of Structures.
Method for Determination
of the Fire Resistance of
Ventilation Ducts

Design Guide for the

Fire Protection of
Buildings 1996
(Insurers Rules for the
Protection of Building)

ISO6944 (1985)
Fire Resistance Tests
Ventilation Ducts
BS 7346 Part 2 (1990)
Specification for
Powered Smoke & Heat
Exhaust Ventilators

BS 8313 (1989)
Code of Practice for
Accommodation of
Buildings Services
in Ducts

London District
Surveyors Association
BS 476 Part 20 (1987)
Fire Tests on Building
Materials of Structures.
Method for Determination
of the Fire Resistance of
Elements of Construction
(General Principals)

BS 476 Part 21 (1987)

Fire Tests on Building
Materials of Structures.
Method for Determination
of the Fire Resistance of
Loadbearing Elements of
Construction

BS 476 Part 22 (1987)

Fire Tests on Building
Materials of Structures.
Method for Determination
of the Fire Resistance of
Non-Loadbearing
Elements of Construction

Loss Prevention Council

(Fire Safety Guide No1

Fire Safety in Section 20
Buildings 1990)
(Fire Safety Guide No2
Fire Safety in Atrium
Buildings)

Department of Health
Firecodes
HTM81 (Fire Precautions
in New Hospitals)
HTM85 (Fire Precautions
in Existing Hospitals)
HTM88 (Fire Precautions
in NHS Housing for
Mentally Handicapped
HTM94 (Fire Precautions
in New Old Peoples
Homes)

3. FLAMEBAR B.W.11
Fire Resistant Ductwork
Analysis and Performance
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11

FLAMEBAR B.W.11 - Single Source Responsibility - Certificate of Conformity

FLAMEBAR B.W.11 - Flexibility in Design
FLAMEBAR B.W.11 - Construction of FLAMEBAR B.W.11 Fire Duct
FLAMEBAR B.W.11 - System Integrity - Ancillary Components
FLAMEBAR B.W.11 - Panel Construction
FLAMEBAR B.W.11 - To BS 7346 Insulation Temperatures
FLAMEBAR B.W.11 - Air Temperatures at Various Distances from Duct
FLAMEBAR B.W.11 - Guide to Fire Protection of Ductwork
FLAMEBAR B.W.11 - Fire Resistance Criteria
FLAMEBAR B.W.11 - Supports and Hangers
FLAMEBAR B.W.11 - Construction Standards

FLAMEBAR B.W.11 Rectangular Fire Duct

3.1. Single Source - Responsibility

- Certificate of Conformity
When considering the use of Fire Resistant Ductwork, issues such as Single Source
Responsibility and Certificates of Conformity are often overlooked. When specifying

FLAMEBAR B.W.11 you are assured that every process from design to installation is
directly controlled.

Single Source Responsibility means exactly what it states, that from design through
manufacture, spray coating and installation there is a single source responsibility.

FLAMEBAR B.W.11 Flat Oval Fire Duct

Furthermore once all the installation is complete and all contractual commitments are
fulfiled a Certificate of Conformity is issued to the client. This confirms the periods
of fire resistance installed and confirms compliance with the relevant criteria of BS
476 Part 24 (1987) and ISO 6944 (1985).

This document underlines our commitment to providing the best and ultimately most
fire safe installations available.

3.2. Flexibility in Design

FLAMEBAR B.W.11 offers complete flexibility in design - rectangular, flat oval and
circular ducts are available.

FLAMEBAR B.W.11 Circular Fire Duct

The construction of the initial galvanised sheet steel duct means that all FLAMEBAR
B.W.11 Fire Ducts have normal standards of air tightness and are therefore easily
capable of being successfully tested.

As well as profile flexibility as depicted in the previous illustrations, FLAMEBAR B.W.11

Fire Ducts can also be supplied as detailed below:

Single Sided

Two Sided

Flat Oval

Three Sided

Four Sided

Circular
Any other
shape

3.3. Construction
FLAMEBAR B.W.11 Fire Duct is constructed from galvanised sheet steel manufactured to
an enhanced standard, then degreased and factory fire sprayed with FLAMEBAR B.W.11
which is a specially formulated water based compound. This contains selected mineral
filters in a low permeability elastomeric binder to a thickness of approximately 1mm to
give a finished product which has been successfully tested for international use under
Cellulosic Fire Conditions in excess of 4 hours duration. Ductwork is produced in sections
and is assembled on site utilising tested fireproof gaskets/sealants.

The unique properties of FLAMEBAR B.W.11 has enabled us to design a low density,
highly durable material which accommodates induced stress arising from extreme and
varying conditions e.g. Climatic Moisture and Structural Loading Variations, and the effect
of thermal shock during a fire.

The completed system has been completed to BS 476 Part 24 (1987) and ISO 6944

10

(1985) up to temperature of 1133 OC, thereby facilitating complete design freedom should
a fire engineering approach be adopted.

3.4. System Integrity

Ancillary Components .
FLAMEBAR B.W.11
Fire Resistant Attenuators

FLAMEBAR B.W.11
Fire Resistant VCDs

FLAMEBAR B.W.11
Fire Resistant Access Doors

FLAMEBAR B.W.11
Cable and Pipe Enclosures

Some of the additional features that can be incorporated in

FLAMEBAR B.W.11 Fire Duct Systems

1. Access Doors.
2. Control Device Housings.
3. Volume Control Dampers.
4. Cable and Pipe Enclosures.
5. Internal Flanging.

6. Penetration Seals between Compartments.

7. Protection can be applied to fans, silencers, etc.
(If suitably constructed)

11

3.5. Panel Construction

FLAMEBAR B.W.11
Fire Rated Ductwork
FLAMEBAR B.W.11 ductwork can either be constructed in flanged lengths of duct, which
are then bolted together to make a run of ducting, or in panel form. This construction is
especially useful for ducts of large cross-section and can be used on any size of duct up
to 25M x 3M.

SOME OF THE FLAMEBAR B.W.11 PANEL CONSTRUCTION SYSTEM BENEFITS

Tested for up to 4 hours Stability, Integrity & Insulation to BS 476 pt 24 (1987)

and ISO 6944 (1985) for Ventilation Fire Duct, Smoke Duct & Kitchen Extract
ductwork.

When insulation rating is required panels are pre-insulated at the factory.

Smooth cleanable internal finish.

Total flexibility in the design and construction of the duct.

Can be sent to site flat packed ready to bolt up.

Lightest fire duct system available.

The panels are delivered to site precoated on the outside face with FLAMEBAR B.W.11 and
are then bolted together incorporating FLAMEBAR intumescent gasket strip to form the
required duct cross-section.

12
Typical Panel Constructed Duct

Examples of Panel
Configurations

U AND PANEL CONFIGURATION

4 L PANEL CONFIGURATION

2 U CONFIGURATION

Typical Methods of Panel

Manufacture
Depending on Fire Resistance, manufacture should be to FLAMEBAR B.W.11
Construction Standards.

TYPE B
PANEL

1m MAX

TYPE A
PANEL

JOINT ANGLES
AND STIFFENERS
FIXED AT SPECIFIED
CENTRES

1m MAX

NOTE:LARGEST AREA
WITHOUT
STIFFENING1M 2

SHEET THICKNESS TO
SPECIFIED STANDARD
SPRAYED WITH
FLAMEBAR B.W.11

2m MAX

DUCT
BOLT TO ADJACENT
TYPE A PANEL

DUCT
MINERAL WOOL THICKNESS
VARIES DEPENDING ON
INSULATION RATING

SHEET THICKNESS
TO SPECIFIED
STANDARD SPRAYED
WITH FLAMEBAR B.W.11

TYPE A PANEL

DUCT
INSIDE
TYPICAL CORNER DETAIL
OF CONSTRUCTED DUCT

TYPE A PANEL

FLAMEBAR B.W.11
FIRE DUCT
SANDWICH PANEL
CONSTRUCTION
WITH VARYING MINERAL
WOOL INSULATION

GSS TRAY

13

3.6. FLAMEBAR B.W.11

to BS 7346 Insulation Temperatures

FLAMEBAR Solution When Lower Insulation

Temperature Required

All FLAMEBAR B.W.11 Fire Ducting has been fully tested to BS 476 Part 24 (1987) and
ISO 6944 (1985) for stability and integrity up to 4 hours. However, where lower
installation temperatures are required due to ducting being rated the same as the smoke
extract fan or a fire engineering consultant having determined a fire engineering solution.
B.W.11 product, either on its own or with the addition
We are able to offer our
of various thicknesses of insulation depending upon the insulation fire rating required.
To satisfy the low temperature smoke requirement, we have tested
B.W.11 duct
without additional insultant to the principles of BS476 Part 24 (ISO 6944) at 400c for 2 hours.

Smoke Extract Duct Test in Accordance with BS 7346 - Fire Inside Duct
Mean Furnace and Duct Surface Temperatures
FIRE TEST Nos 615, 616 & 621

700

650 OC
600 OC

600
BS 7346
TIME - TEMPERATURE CURVE

TEMPERATURE ( OC)

500

FURNACE TEMP

400 OC

400
300 OC

300

250 OC

200

B.W.11

B.W.11 WITH
25mm INSULATION

INSULATION FAIL TEMP. 140 OC + AMBIENT

100

B.W.11 WITH 50mm INSULATION

EXTERNAL TEMPERATURE OF DUCT

0
0

50

100

150

200
250
TIME (MINUTES)

300

350

400

Minimum Periods of Fire Resistance for Fire Rated Ductwork

Example showing a typical fire duct run passing through different fire rated compartments

1st FIRE COMPARTMENT

30 MIN FIRE
RESISTANT DUCT

60 MIN FIRE
RESISTANT DUCT

60 MIN FIRE
RESISTANT DUCT

2nd FIRE COMPARTMENT

3rd FIRE COMPARTMENT

4th FIRE COMPARTMENT

30 MIN FIRE
COMPARTMENT WALL

14

60 MIN FIRE
COMPARTMENT WALL

30 MIN FIRE
COMPARTMENT WALL

From the example, it can be seen that when the fire duct passes from the 2nd to the 3rd fire compartment, the
fire resistance of the duct increases in line with the rating of the fire compartment wall. This rating is not reduced
in the 4th compartment, despite the reduced rating of the fire compartment wall between the 3rd and 4th fire
compartments.

Important Note:
If the fire duct is for extracting smoke, it must also maintain a minimum of 75% of its overall cross-sectional
area over the total length of the duct, including the 1st fire compartment. Therefore smoke extract ductwork in the
1st fire compartment must always be tested to BS 476 Part 24 (1987) for stability and integrity only.

450

3.7. FLAMEBAR B.W.11

Air Temperatures at Various Distances from Duct
Without Additional Insulation
Compartment walls and floors will have a prescribed fire resistance in terms of stability,
integrity and insulation for between 30 and 240 minutes. It is therefore essential for fire
security, that where compartmentation boundaries are penetrated by fire duct, the fire
separation and the performance criteria of the penetration wall or floor is maintained, and
that the duct should not act as a conduit along which fire may spread to other areas.
In all cases, the time period for stability and integrity should be at least equal to that
required by the penetration element. However, controlling Authorities and engineered
solutions have in many circumstances waived the insulation requirement. If the ductwork is
within the first compartment (see example) it will not need to be insulated and if the fire
duct has not been fire insulated for a give period to BS 476 Part 24 (1987), sufficient
distance must be maintained between the fire duct and any adjacent combustible material.
BS 5588 Part 9, Appendix Clause A4, recommends a minimum of 500mm be maintained for
bare metal ductwork.
The graph below gives the air temperature, taken at various distances away from our
FLAMEBAR B.W.11 fire duct. It should be noted that the insulation failure temperature, as
per BS 476 Part 24 (1987), is of a minimum of 140 OC, plus ambient temperature, ie
approximately 160 OC.

FLAMEBAR B.W.11 fireduct without additional insulation

Indicative temperature measurements in air
adjacent to a duct B (fire inside) test to
BS 476 Part 24 (1987) and ISO 6944 (1985).
500

DISTANCE FROM SURFACE OF DUCT IN mm

450

TEMPERATURES TAKEN AT 1 HOUR, 2 HOURS & 4 HOURS.

400
350
300

TIME 120 mins

FURNACE TEMP
1029 OC

250

TIME 240 mins

FURNACE TEMP
1133 OC

200
150
100

TIME 60 mins
FURNACE TEMP
925 OC

50

L.P.C. TEST No TE 87473

0
0

10

20

30 40 50 60 70 80 90 100 110 120 130 140

TEMP OC MEASURED AT VARIOUS DISTANCES FROM DUCT

15

FIRE OUTSIDE DUCT

3.8. FLAMEB
Fire Resista

FIRE DUCT RATED FOR STABILITY

AND INTEGRITY TO PREVENT FIRE
GETTING INSIDE DUCTWORK

Guide to Fire
of Duc

Fire Resistance Periods Afforded by FLAMEBAR B.W.11 Fire Resistant Ductwork

Note Table Designed as Indicative Guide Only - Actual Compartmentation Requirements Must
be Verified by Others
Quoted Periods as Tested in Accordance with BS 476 Part 24 (1987) & ISO 6944 (1985)
1) Insulation - Fire inside duct, temperature rise exceeds either (1) 140 OC as an average
value, or (2) 180 OC as a maximum value on duct surface in compartment adjacent to fire
seat.
2) Insulation - Fire outside duct, temperature rise exceeds either (1) 140 OC as an average
value, or (2) 180 OC as a maximum value on internal duct surface in fire seat.

Yes

3) Insulation - Fire outside duct, temperature rise exceeds either (1) 140 OC as an average
value, or (2) 180 OC as a maximum value on duct surface in compartment adjacent to fire
seat.

Car park
mechanical extract

Pressurisation
systems

Is extract contained
within single fire zone

Will outer face of duct be

close to combustibles,
or in an escape route?

Yes

Yes

No

Minimum Stability &

Integrity ratings

Fire resistance (In line

with Compartment Criteria)
Stability & Integrity
60, 120 or 240 minutes

Does air supply temperature

within duct have to be protected?

Basement below 10m

90 mins
Basement below 10m
60 mins

Will outer face of duct be

close to combustibles,
or in an escape route?

Yes

No

No

Yes

Will outer face of

duct be close to
combustibles, or
in an escape route?

Yes

No

Above ground up
to 5m 30 mins
Above ground up
to 20m 60 mins

Yes

Above ground up
to 20m 90 mins

Fire resistance (In line

with Compartment Criteria)
Stability & Integrity
60, 120 or 240 minutes

16

Fire resistance (In line with Compartment Criteria)

1
Stability & Integrity
Insulation - Fire Inside Duct
60, 120 or 240 mins 64 minutes
60, 120 or 240 mins 120 minutes

No

Fire resistance (In line

with Compartment Criteria)
Stability & Integrity
60, 120 or 240 minutes

Fire resistance (In line

with Compartment Criteria)
Stability & Integrity
60, 120 or 240 minutes

Fire resistance (In line

with Compartment Criteria)
Stability & Integrity
60, 120 or 240 minutes
Fire resistance (In line with Compartment Criteria)
3
Stability & Integrity
Insulation - Fire Outside Duct
60, 120 or 240 mins 210 minutes Insulation
60, 120 or 240 mins 240 minutes Insulation
Fire resistance (In line with Compartment Criteria)
2
Stability & Integrity
Insulation - Fire Outside Duct
60, 120 or 240 mins 44 minutes Insulation
60, 120 or 240 mins 60 minutes Insulation

Fire resistance (In line

Stability & Integrity
60, 120 or 240 mins
60, 120 or 240 mins

FIRE INSIDE DUCT

BAR B.W.11
nt Ductwork

FIRE DUCT RATED FOR STABILITY

AND INTEGRITY TO PREVENT FIRE
GETTING OUT OF DUCTWORK

e Protection
ctwork
Will duct system have a fan?

NB. If in doubt use Yes route

No

Will fan operate in the

event of a fire?
For kitchen
extract systems

Will fire have direct access to

the inside of duct? ie. through
vent. grille etc

No

Yes
Yes

Is fire protection
required on outside as
well as inside of duct?

Will outer face of duct

be close to combustibles,
or in an escape route?

Will fan operate to

draw air out of
system to act as
smoke extract

No

Yes

Will outer face of

duct be close to
combustibles, or
in an escape route?

Will fire protection

be required for
smoke inside
duct only?

No

No

Fire resistance (In line

with Compartment Criteria)
Stability & Integrity
60, 120 or 240 minutes

Will fire be on outside

of duct?

Yes

No
Fire resistance (In line
with Compartment Criteria)
Stability & Integrity
60, 120 or 240 minutes

e with Compartment Criteria)

1
Insulation - Fire Inside Duct
64 minutes
120 minutes

Will outer face of

duct be close to
combustibles, or in
an escape route?
Yes

Fire resistance (In line

with Compartment Criteria)
Stability & Integrity
60, 120 or 240 minutes

No

Fire resistance (In line

with Compartment Criteria)
Stability & Integrity
60, 120 or 240 minutes

No

Yes

No

Fire resistance (In line

with Compartment Criteria)
Stability & Integrity
60, 120 or 240 minutes

Fire resistance (In line

with Compartment Criteria)
Stability & Integrity
60, 120 or 240 minutes

Fire resistance (In line with Compartment Criteria)

1
Stability & Integrity
Insulation - Fire Inside Duct
60, 120 or 240 mins 64 minutes
60, 120 or 240 mins 120 minutes

Fire resistance (In line with Compartment Criteria)

1
Stability & Integrity
Insulation - Fire Inside Duct
60, 120 or 240 mins 64 minutes
60, 120 or 240 mins 120 minutes

Yes

Fire resistance (In line

with Compartment Criteria)
Stability & Integrity
60, 120 or 240 minutes

Yes

Will outer face of

duct be close to
combustibles, or in
an escape route?

Does air supply

temperature within
duct have to be
protected?
No

No

Yes
Yes

No

Fire resistance (In line with Compartment Criteria)

1
Stability & Integrity
Insulation - Fire Inside Duct
60, 120 or 240 mins 64 minutes
60, 120 or 240 mins 120 minutes
Fire resistance (In line with Compartment Criteria)
3
Stability & Integrity
Insulation - Fire Outside Duct
60, 120 or 240 mins 210 minutes Insulation
60, 120 or 240 mins 240 minutes Insulation

17

3.9. Fire Resistance

Criteria
Application

Fire Exposure

Smoke
Extract

Fire
Fire
Fire
Fire
Fire

Inside
Inside
Inside
Inside
Inside

Fire Duct

Fire
Fire
Fire
Fire
Fire
Fire
Fire
Fire
Fire
Fire

Kitchen
Extract

Fire
Fire
Fire
Fire
Fire
Fire
Fire
Fire

or
or
or
or
or

Outside
Outside
Outside
Outside
Outside

Tested in Accordance with BS 476

Part 24 (1987) and ISO 6944 (1985)

Tested in Accordance
with BS 7346
Time/Temp Heating
Curve

Fire Resistance Time-Minutes

Stability
Integrity
Insulation

Low Temp
Insulation
Time/Mins

Temperatures
up
to OC

Approx. Product
Thickness mm()

240
240
240
240
240

240
240
240
240
240

10
30
60
90
120

210
240
240
-

400
600
650
-

1
25
50
80
100

(0.04)
(1)
(2)
(3.15)
(4)

Inside
Inside
Inside
Inside
Inside
Outside
Outside
Outside
Outside
Outside

240
240
240
240
240
240
240
240
240
240

240
240
240
240
240
240
240
240
240
240

10
30
60
90
120
15
60
90
210
240

210
240
240
240
240
240
-

400
600
650
400
600
650
-

1
25
50
80
100
1
25
40
50
80

(0.04)
(1)
(2)
(3.15)
(4)
(0.04)
(1)
(1.6)
(2)
(3.15)

Inside
Inside
Inside
Inside
Inside
Outside
Outside
Outside

240
240
240
240
240
240
240
240

240
240
240
240
240
240
240
240

10
30
60
90
120
10
44
60

1
25
50
80
100
1
50
100

(0.04)
(1)
(2)
(3.15)
(4)
(0.04)
(2)
(4)

3.10. Supports and

Hangers
As it is known that tensile strength of steel reduces
with temperature, it has been calculated and tested
by the Loss Prevention Council that based on the
original strength of steel for supports of 430
N/mm 2. Fire duct supports should be sized based
on:Fire Duct rated for 60 minutes 925 OC (1697 OF).
Tensile strength of 15N/mm 2.
Fire Duct rated for 120 minutes 1029 OC (1884 OF).
Tensile strength of 10N/mm 2.
Fire Duct rated for 240 minutes 1133 OC (2071 OF).
Tensile strength of 6N/mm 2.

Weight of FLAMEBAR B.W.11 Fire Duct

Total weight of up to 2 Hour Fire Duct without
insulation = 10.98 kg/m 2. (2.24lb/ft 2)
Total weight of up to 2 Hour Fire Duct with 50 mm
insulation = 16.23 kg/m 2. (3.33lb/ft 2)
Total weight of up to 2 Hour Fire Duct with 100 mm
insulation = 21.48 kg/m 2. (4.40lb/ft 2)
Total weight of up to 4 Hour Fire Duct without
insulation = 14.12 kg/m 2. (2.89lb/ft 2)
Total weight of up to 4 Hour Fire Duct with 50 mm
insulation = 19.37 kg/m 2. (3.97lb/ft 2)
Total weight of up to 4 Hour Fire Duct with 100 mm
insulation = 24.62 kg/m 2. (5.05lb/ft 2)

18
Above weights are based on 1000mm x 1000mm (40 x 40) typical standard ductwork per linear metre.

When designing and testing Fire Resistant Ductwork it is critical that the reduction in
tensile strength of steel under fire load is given adequate consideration. This applies
to hangers (studding) and bearers, but it is equally important that due consideration
is given to the performance of the fixing system under fire load.

It must be recognised that the pull out load of an anchor under fire conditions is
significantly less than at ambient temperature. By specifying FLAMEBAR B.W.11 you
can be confident that these issues have been adequately addressed.

Table Showing Typical Anchor and Hanger Sizes Required for

2hr. Stability and Integrity FLAMEBAR B.W.11 Smoke Duct
Duct Size

Duct area per

metre run

Total weight
per metre
run of duct
+BW11

Bearer
spacing
mm

Weight on
each bearer

Weight on
each anchor

Max test load

that Hilti HKD
anchor will
withstand in
a fire situation

Size of
anchor &
hanger used
to provide
added safety

Sum of 2
sides 600

1.2m 2

14.4 kg

1500

21.6 kg

10.8 kg

30 kg
= 6mm HKD

M8

Sum of 2
sides 800

1.6m 2

19.3 kg

1500

28.95 kg

14.5 kg

30 kg
= 6mm HKD

M8

Sum of 2
sides 1200

2.4m 2

33.65 kg

1500

50.7 kg

25.2 kg

30 kg
= 6mm HKD

M8

Sum of 2
sides 1600

3.2m 2

51.1 kg

1500

76.6 kg

38.3 kg

40 kg
= 6mm HKD

M8

Sum of 2
sides 2000

4.0m 2

65.7 kg

1500

98.5 kg

49.5 kg

80 kg
= 10mm HKD

M10

Sum of 2
sides 3000

6.0m 2

98.7 kg

1500

148 kg

74 kg

80 kg
= 10mm HKD

M12

Sum of 2
sides 4000

8.0m 2

131.5 kg

1500

197 kg

98.5 kg

120 kg
= 12mm HKD

M12

Sum of 2
sides 5000

10.0m 2

202 kg

1500

303 kg

152 kg

300 kg
= 16mm HKD

M16

SUPPORT STEEL
TO SPAN HOLE

SIZING
OF GALLOWS
BRACKET TO
SUIT DUCT

CONCRETE
FLOOR SLAB

Support sizes dependent on

stability and integrity rating
TYPICAL ALTERNATIVE
ARRANGEMENTS FOR
SUPPORTS

50 X 50 R.S.A
FRAME

MINERAL WOOL

Typical Vertical & Horizontal

Support Arrangements

3mm THICK FLAT BAR

CALCIUM
SILICATE
BOARD

Ensure that fixing into slab

is capable of supporting the
weight shown on the chart.
(Note, all parts of anchor
to be steel)

50mm

50mm

N.B. If ordered, several fire stop details can be

provided, please refer to office for details.

19

3.11. Construction
Standards
A series of Construction Standards are produced that directly relate to the requirements
of each individual project. These Standards represent varying periods of fire resistance,
ductwork profile and operational requirement of the duct system (i.e. smoke extract,
ventilation duct or kitchen extract). Detailed below is a typical construction standard.

Typical Construction Standard

Each standard is laid out in a clear and concise way. From these standards it is
possible to easily identify flange requirements, support requirements, dimensional data
etc. It is important to remember that these standards replicate exactly the methods
used in actual fire tests therefore ensuring optimum system performance under the
required fire conditions.

20

4. Penetration Seals
Between Fire Compartments
If specified we can provide fir stopping compartments as part of our installation
service. Detailed below are two typical fire rated ductwork stoppings, as tested to
BS 476 Part 24 (1987) and ISO 6944 (1985).
1) Mineral Wool and Calcium Silicate Board Fire Stopping
HT MINERAL
WOOL PACKING

100 MIN.

SCREW FIXINGS
CALCIUM SILICATE
BOARD ( 30mm THICK )

100 MIN.

SCREW FIXINGS

HT MINERAL
WOOL PACKING
CALCIUM SILICATE
BOARD ( 30mm THICK )

3mm THICK FLAT BAR

ON PENETRATIONS WITH
LONGEST SIDE GREATER
THAN 2m, TIE BAR TO BE
PROVIDED (min 16mm DIA )

FLANGE
50 MAX.
OR WITHIN WALL

50 x 50 R.S.A

2) FLAMEBAR FPS 1000 Fire Stopping

3mm THICK FLAT BAR

FLANGE
50 MAX.
OR WITHIN WALL

50 x 50 R.S.A

ON PENETRATIONS WITH
LONGEST SIDE GREATER
THAN 2m, TIE BAR TO BE
PROVIDED (min 16mm DIA )

5. Pro-Forma
Specification Example
FLAMEBAR B.W.11 Fire Resistant Ductwork to be manufactured by Fire Protection
Limited (or other authorised licensee) for our Ventilation/Smoke/Kitchen Extract/Supply
System to comply with BS 476 Part 24 (1987) & ISO 6944 (1985),
for ........Hours Stability ........Hours Integrity and ........Hours Insulation.
Ductwork to be Rectangular/Flat Oval/Circular construction, complying with Building
Regulations Class 0 requirements.
The Duct to be a composite Fire Duct manufactured to Method 3 of BS 5588 Part 9
factory produced. Once erected, to be pressure tested, if required, by client, to HVCA
Standard DW 143, Pressure Classification Class ........
On Kitchen Extract Ductwork, Access Doors to be installed at a minimum distance
between doors of 3 metres as required by BS 5588 Part 9 (1989).

21

6. Standards
The range of FLAMEBAR B.W.11 Fire Duct has been
tested by the Loss Prevention Council in accordance
with BS 476 Part 24 (1987) and ISO Standard 6944
(1985), for vertical and horizontal ductwork, with fire
inside and outside the duct, in excess of 4 hours
Stability, Integrity and Insulation, for Ventilation
Ductwork, Smoke Extract Ductwork or Kitchen Extract
Ductwork.

FLAMEBAR B.W.11 Fire Duct has also been tested by

the Loss Prevention Council, in accordance with
BS 476 Part 7 (1987) for surface spread of flame in
accordance with the Flame Spread Classification given
in the Standard.
FLAMEBAR B.W.11 Fire Duct has also been tested by
the Loss Prevention Council to BS 476 Part 6 (1989)
for fire propagation, confirming that the product can
be defined as a Class O Material in accordance with
the Building Regulations 1991.
FLAMEBAR B.W.11 Fire Duct has also been tested by
L.U.L. to BS 6853 and satisfied the Fire Safety Code of
Practice requirements for smoke emission and toxic
fume emission.
FLAMEBAR B.W.11 Fire Duct has the U.S.A.
Underwriters Laboratory UL Classification for up to 4
Hr. Fire & Smoke Ductwork.
FLAMEBAR B.W.11 has been tested by Underwriters
Laboratory in the USA to determine compliance with
NFPA 90A (Installation of Air Conditioning and
Ventilating Systems) for flame spread and smoke
development with the following results:
NFPA
Stipulation
BW11 Results

Flame Spread
not to exceed
25
9.4

Smoke
Development no
higher than 50
0.2

Test conducted in accordance with UL Standard 723

Test for Surface Burning Characteristics of Building
Materials (ASTM E84).

FLAMEBAR B.W.11 Fire Duct has also passed the hose

stream test to ASTM - E119 with water pressure of
207 KPa (30 psi) for 2 1/ 2 mins.
Impact Test of FLAMEBAR B.W.11 Fire Duct
Impact test to BS 5669, in which a dart imparts
44.15 joules (32.5 ft pound force) at maximum drop,
resulting in a small indentation which passes under
the criteria of BS 5669. FLAMEBAR B.W.11 Fire Duct
also has undergone impact testing to the requirements
of Appendix A BS 5588 Part 5.
Leakage Testing of FLAMEBAR B.W.11 Fire Duct
The construction and sealing of the Fire Duct System
allows the ductwork to be tested up to Class D high
pressure, if required by the clients specification, which

22

has a leakage limit of .0001 x P 0.65 litres per second

per sq. metre of duct surface area, as laid down by
the HVCA Specification DW 143. Higher pressures and
lower leakage rates can be achieved if required by the
Clients specification.
Exterior Weathering of FLAMEBAR B.W.11 Fire Duct
Duplicate samples were placed on the exterior
weathering frame and left totally exposed from
January 1993. The results so far show:
1. Some dirt pick-up which can be washed off.
2. No mould growth.
3. No chalking.
4. Material has remained totally intact.
Considering the length of time the samples have been
exposed, the material is in good condition.
Artificial Weathering of FLAMEBAR B.W.11 - OUV
Weatherometer
The samples undergoing artificial weathering have
undergone over 22000 hours of alternate UV and
condensation cycling which is extremely excessive in
duration terms, normally 1000 hours is sufficient to
predict whether a material is suitable for exterior/semiexposed conditions. 22000 hours is equivalent to 60
years external exposure.
Expansion of FLAMEBAR B.W.11 Fire Duct
As all steel expands with temperature, there will
naturally be an expansion of Fire Duct under fire
conditions as follows:
At 1100 OC an expansion of 0.01562mm per mm
(0.016 in per in)
At 600 OC an expansion of 0.00852mm per mm
(0.008 in per in)
At 430 OC an expansion of 0.006106mm per mm
(0.006 in per in)
Thermal Properties of FLAMEBAR B.W.11 Fire Duct
U value - thermal transmittance.
BW11 without insulation = 5.0 w/mk 2k
(0.88Btu/ft 2h 0f)
BW11 with 50mm insulation = 0.833 w/m 2k
(0.147Btu/ft 2h 0f)
BW11 with 100mm insulation = 0.48 w/m 2k
(0.08Btu/ft 2h 0f)
Chemical Resistance of FLAMEBAR B.W.11 Fire Duct
The coating has been tested in:
Standard 10% solutions of the following acids:
Hydrochloric, Nitric and Sulphuric.
Standard 10% solutions of the following Alkalies:
Sodium Hydroxide and Potassium Hydroxide.
The following solvents: Xylene and Acetone.
After 10 days total immersion, all the above chemicals
failed to cause a Breakdown of the product structure.

7. System Advantages
Single Source Responsibility
1.
2.
3.
4.

The design of all FLAMEBAR B.W.11 Systems are to a certified standard.

All FLAMEBAR B.W.11 Fire Duct is manufactured and sprayed to QA ISO 9002 Standard.
All FLAMEBAR B.W.11 Fire Duct is erected to QA ISO 9002 Standard.
Certificate of Conformity is issued following final inspection, certifying compliance with all necessary regulations.

Testing
All FLAMEBAR B.W.11 Fire Duct has been tested to:
BS 476 Part 24 (1987) & ISO 6944 (1985) for up to 4 hours Stability, Integrity & Insulation.
BS 476 Part 6 for Fire Propagation Class O
BS 476 Part 7 for surface spread of flame

Weight: FLAMEBAR B.W.11 Fire Duct is the lightest Fire Duct system available.
Shape: FLAMEBAR B.W.11 Fire Duct can be manufactured in Rectangular, Flat Oval or Circular.
Impact Resistance: FLAMEBAR B.W.11 systems are impact resistant to BS 5669 and to BS 5588 Part 5,
Appendix A.

Moisture Absorption: FLAMEBAR B.W.11 systems are non-hygroscopic and have been tested in an artificial
Weatherometer to an equivalent of 60 years external exposure.

Chemical Resistance: FLAMEBAR B.W.11 Fire Duct is chemically resistant to many acids and solvents and
has excellent resistance to chemical attack.

Smoke and Toxic Fume Emission: FLAMEBAR B.W.11 Fire Duct has been tested to BS 6853 for Smoke
Emission and Toxic Fume Emission.

Pressure Testing: FLAMEBAR B.W.11 Fire Duct has the same frictional resistance to GSS ductwork, and can be
pressure tested to 2500 pascals (10 wg) with a leakage rate of less than 0.16 litres per second per m 2 (0.032 ft 3
per minute per ft 2) of surface area.

Anti Drumming: FLAMEBAR B.W.11 Fire Duct has a damping co-efficient to BS AU125(1966) of 19db per
second decay rate.

Inline Plant: Inline Plant can be treated with FLAMEBAR B.W.11, if suitably constructed.
Acoustic Properties: FLAMEBAR B.W.11 Fire Duct achieves a Sound Reduction Index to BS 2750 Part 3
(1980) as tabled below:
Frequency (Hz)

Systems
63
10.2

125
11.7

250
16.7

500
21.7

1K
27.7

2K
32.7

4K
37.7

8K
43.7

dB

B.W.11 + 60kg/m 2,
50mm insulation

11.0

12.5

17.5

22.5

28.5

33.5

38.5

44.5

dB

B.W.11 + 105kg/m 2,
50mm insulation

13.4

14.9

19.9

24.9

30.9

35.9

40.9

46.9

dB

B.W.11

Size: FLAMEBAR B.W.11 Fire Duct is fully certificated for any size of Ductwork in the vertical and horizontal plane
up to 25m x 3m (82 x 10) cross sectional area.

Cleaning: The smooth internal finish of FLAMEBAR B.W.11 Systems enable easy cleaning of the ductwork
therefore it is ideal for kitchen extract duct installations.

Colour: FLAMEBAR B.W.11 Fire Duct without insulation has a monolithic spray texture with natural buff finish.
FLAMEBAR B.W.11 systems can also be overpainted or sprayed with water based paint to obtain any desired
colour.

23