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Omaha Public Power District1623 HARNEY a OMANA. NESRASKA 681C2 a T E L, EP H O N E 536 4000 AREA C O D E 4 C '2

July 9, 1979

Director of Nuclear Reactor RegulationAffN: Mr. Robert W. Reid, ChiefOperating Reactors Branch No. 4U. S. Nuclear Regulatory CommissionWashington, D. C. 20555

Reference: Docket No. 50-285

Gentlemen:

As a result of a conference call held on May 23, 1979 between theOmaha Public Pcver District and members of the Commission's staff, five(5) copies of the following information is provided by attachment:

Attachment 1 - Revision 1 to the Fort Calhoun cable separationanalysis dated September 28, 1978

Attachment 2 - Pesponses to questions regarding the cableseparation analysis -

Attachment 3 - Responses to questions regarding the FortCalhoun fire detector analysis dated January8, 1979 -,

Sincerely,

b '\V| > .,

-,~p._O. T. E.,Short

y * Assistant General Manager

TIS /KJM/BJH:cb'

I [.Attachments 9w %acc, _ _ ,. _ , 1 1,, , acRa.

h( h1333 New Hampshire Avenue, N.W.Washington, D. C. 20036 L

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ATTACHMENT I

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FORT CALHOUN UNIT 11'

Revisions to Cable _ Separation AnalysisyDated September 28, 1978 R

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Please substitute attached sheets in place of Page 4 of the Cable SeparationAnalysis submitted September,1978.

NOTES: 1. This revision is a result of detailed design effort, whichis under progress for this modification.

2. The revisions'from the previous submittal are noted withvertical bar in the side margin.

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Revision 1, June 22, 1979

II. Fire Areas Not Meeting All Safe ShutdownCable Separation Requirements

The following fire areas contain some redundant cables ~ required forsafe shutdown where there are no alternate methods (including manualoperation of valves) of performing the same safe shutdown function:

FIRE AREA

No. Title and Description

6 Cable and Personnel Corridor Area

Redundant cables of Low Pressure SafetyInjection Pumps SI-1 A and -1B and Con-tainment Spray Pumps SI-3A, -3B, and -3Chave 5 feet minimum horizontal separationand 0 feet minimum vertical separation.*Cables ED-lll, ED-112, ED-4189, ED-4191,ED-4192, ED-9384, ED-9385, ED-4159, ED-9531will be protected or rerouted to makeSI-3C available to perform the plant shut-down cooling function in case of a fire inarea 6.

31 Intake Structure

Redundant cables of Raw Water Pumps AC-10A,-10B, -10C and -10D are routed in this firearea. AC-10A and AC-10D are located in twoseparate concrete cells. AC-10B and AC-10Care located in third concrete cell. Powerand control cables for these pumps have1 foot minimum horizontal separation and 0

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feet minimum vertical separation * at ele-vation 985' in recirculating water pump area-(part of intake structure). Redundant cablesof raw water valves HCV-2850, -2851, -2852,-2853, -2874A, -2874B, -2876A, and -2876B,which are also routed in this fire area,have 1 foot minimum horizontal separation

; and 1 foot minimum vertical separation inrecirculating water-pump area'(part ofintake structure) at-elevation 985'.

* Conduits, cables or trays installed at-same elevation are considered to have0 feet ~ vertical separation.

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Revision -1,- June,' 22, :1979-r s1

I FIRE AREA

No. Titie'and Description

i 31 Intake Structure (Continued)

b Necessary cables will be protected to makeRaw Water Pump AC-10B and related valves'

available' to provide the required plant-i shutdown cooling capability in case-ofj fire in Area 31. The cables involved are

as follows:4

{ EB-67, EB-7309E, 7310, EB-7309, EA-7306f- EA-7306A, EB-7307 and EB-7307A.

I EB-67 is power feed for raw-water pump andi shall be protected.

I EB 7309E and EB-7307A are control cablesj of small-lengths routed within concrete cells

provided for AC-10B and AC-10C and have>

! sufficient separation from' cables of AC-10A~

i and AC-10D which are located in two separate| concrete cells.4

[ 7310 is a non safety related power. feed for1 ~ motor space heater and is not considered -

necessary-fo safe shutdown and as such noprotection is required.

EB-7309, EA-7305 and .EB-7307 are' control*

cables which are necessary for plant shut-down and will also be protected.t

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EA-7306A is cable of small leng*th, required1 for operation of valve HG'20/4a , and is - r

routed within concrete cell provided for';-

AC-10A and has sufficient separation from: AC-10D cables. Because of sufficient ~

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! separation no further protection is required.

In summary cables EB-67, EB-7309, EA-7306-and EB-7307 need to be protected. _ All these

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, cables are routed in conduitst 3 hr.Efirerated enclosure will. be -provided around -

| these conduits to protect them from' area -fire. - Cables -EB-7309E, EB-7307A and EA-7606A i

have sufficient separation. Cablec7310 is;~

not required for plant' shutdown.

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*This valve'alsoL has fail safe feature. "

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ATTACHMENT 2

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@_ Separation Analys_fs_ _s,

R.esppnsp Jo,1LRC__questipns

1.) QUESTION:Fire Areas 6 and 31

- Since in this so minimal, we recommend that these cases the separationto reroute the cables ED-lll-3"e licensee be requiredEB-7309, EA-7306, EA-7306A, EB-7307, EB-67, EB-7309E, 7310,RESP-'~~~ONSE: , and EB-7307A.

Fire Area 6 -- Cable ED-lll is rout d~~~~

conduit through Fire Area 6. This cabl in a 3" rigid steele

operation of containment spray pump SI 3Ce is required forwhile doing detailed design it was dis'

ED-112, ED-4189, ED-4190, ED-4191In addition,-

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ED-9385, ED-4159, ED-9431, which ar, ED-4192, ED-9384,covered that cablesFire Area are also required for oe routed through thisRevision 1 dated ' June22,1979 attperation of SI-3C. (Seeachment #1).Relative positionAll these cables are routed in rigid

and SI-1B which are redundant to SI 3C iof these conduits and cables for SI 1Asteel conduit.

11405-E-61 (attached). --

s shown on drawingWe are proposing to provide 3 hrthe conduits as per drawing #13007. fire rated enclosure aroundThe enclosure will utilize a fir.37-SD-36A-2 (attached).'

Pyrocrete). construction (see attached literature fmetal lath covered with Pyrocrete whi he barrier design incorporating,

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is of standard ULc

by providing 2" Pyrocrete over met lThe necessary 3 hour fire rating irom manufacturer ofa lath. s achieved

Also, all cables meet the require(Reference SER Section 4.8)ments of' IEEE 383-1974this area is only 27 minutes, estimated fire loading foris limited to cable insulation (R f, combustible material in this area

e . SER Sec. 5.4.2).Considering that cables are routed ismall portion of cable run is exposed tn conduit, and onlyit is our engineering judgement that3 hour rated fire barrier is inst ll

o Fire Area 6after the propos,edbe adequately protected and the ia

ed, these cables shallrequirements of IEEE-384-1977 paragnstallation will exceedraph 5.1.4

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RESPONSE:Fire Area 31 (Intake Structure) -- As explained in our- (cont.)revised submittal for this fire arearaw water pumps AC-10A and AC-10D are(Attachment #1),

located in twoin third concrete cell (see drawingseparate concrete cells; AC-10B and AC-10C are located

13007.37-E-4033 attached).The cells are interconnected through door size open,ings.

These cables are EB-67, EB-7309E, 7310, EB-7309, EA-7306Our intention is to protect cables for raw water pump AC-10BEA-7306A, EB-7307 and EB-7307A.

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which are routed in conduits.EB-67, EB-7309, EA-7306, EB-7307 are power and control cablesThese conduits run together

other conduits, carrying cables for raw water pump AC-10A,in recirculating water pump area (part of Fire Area 31) with-10C, -100 (see attached drawing 13007.37-E-4033).

Fire loading for intake structure (Fire Area 31) is only14 minutes.

protect these cables from an area fire.We are proposing to provide 3 hour fire rated enclosure tos

will be similar to Fire Area 6 and will be as shown onThe barrier designdrawings13007.37-E-4034 and 13007.37-SD-30A-3, SD-30B 2SD-30C-2.

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EB-7309E, EB-7307A and EA-7306A are control cables ofsmall lengths routed within concrete cell provided forAC-10B and AC-10C and have sufficient separation fromcables for AC-10A and AC-10D and as such no further protectionis considered necessary.

heater and is not required for plant shutdown.7310 is a non safety related power feed for motor space

Considering that fire loading for this area is limited to only14 minutes, all cables are routed in conduits, and cablesmeet requirements of IEEE

383-1974; it is our engineeringjudgement that after 3 hour fire rated barrier is installedthe cables will be adequately protected and the installatiwill meet requirements of IEEE

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384-1977. on

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2.)QUESTION; Fire Areas 32, 34A, 34B and 36 -- In general \

sketches to show what types of barrier, fire stopsare acceptable; however, we recommend that the licensee s b it, these solutions

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coatings will be installed so that the fire protection, and

capabilities of these materials can be evaluatedRESPONSE; Typical detail for the fire barriers i

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13007.37-ES-378-1.The barrier design incorporates metals shown on drawingslath covered with Pyrocrete which is of standard OL

construction (see attached literature from manufacturerof Pyrocrete).The barrier dimensions are per IEEE

384-1977Fire stops where necessary shall be designed per ou

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dated OctoLar 18, 1978Reactor Regulation. addressed to Director of fl

r letter1 uclear>

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ATTACHMENT 3

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Fire Detector Analysis

.Response to NRC Questions

1. ) QUESTION:' The detectors to-be installed _in the safety injection andcontainment spray pump area (Fire Area 2) are shown to beupstream of a cable tray in the room. (DrawingNo.13007-SK-3) _Because of the air flow in this room, a firein the tray might not readily be detected, unless there

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are additional considerations which are not included in-the licensee's analysis. A better location for the twodetectors between columns 6E and 8A would be west of thetray.

RESPONSE: The District located the detectors in an effort to complywith NFPA spacing requirements of 0.7 times the listedspacing for the detector head (NFPA 72E-78 Section 3-5.1)in conjunction with fire loading concentration, air flow,etc.e

The bases for locating the detectors as shown on Drawing' N

No.13007-SK-3 of the analysis is as follows:,

a.) The detectors are centrally located in compliancewith NFPA 72E-78.

b. ) The detectors are located above the safety injection(SI) pumps.

c.) The subject tray contains only two (2)-non-safety -control cables compared to the twenty-eight (28)controls (24 are safety related) and six (6) power(4 are safety related) cables located in- the tray onthe east side of the room.

Thus, the District considers the detectors-acceptable as proposed.

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2.) ' QUESTION: The criteria' used in the licensee's fire detector analysis.-

- are generally more liberal than those in NFPA 72E and-- will probably result in delayed detection of fire,relative to that achievable by compliance with NFPA 72E.'

ANSWER: The District's' analysis conforms to the criteria of NFPA :72E described.below:

a.) NFPA 72E-78, Section 4-4.6, states if beam depths ,

exceed eighteen' (18) inches an'd the beams are more:'

than eight (8) feet on centers, each bay is to betreated as a' separate area: requiring at least onedetector.

The analysis conforms to this criteria, but inaddition, acknowledged that; if the beam centers are1ess than eight (8) feet, the detectors would be.;

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| spaced in alternating bays; and if the beam depths 1

exceea twenty-four. (24) inches, each bay would be'

treated as a separate area requiring at least one.detector, regardless of the on center distance.

b.) Relative to beam depths between eight (8) and *

; eighteen (18) inches, NFPA 72E-.Section 4-4.6' states;j- if beams are eight (8) inches or less in depth, the:; construction can be considered equivalent to a

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smooth ceiling; and if beam construction is greater! than eight (8) inches in depth, spacing shall be'

reduced.

j' The analysis conforms to this criteria, but sincethe NFPA standard does not state what the reduced-spacing should be, engineering judgement was used'to.

determine the reduced spacing. The analysis , -inL every applicable case, did reduce the spacing to-i less than the. 30 feet, as recommended by NFPA for a-

~#' smooth ceiling. configuration.

E Thus, the District considers the' analysis is in conformance with NFPA72E-78 criteria..

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3. ) QUESTION: Fire Areas 10 and 31 have essentially smooth ceilings,and the detector. location and spacing is satisfactory,except detectors proposed for the operating . level of theintake structure (Fire Area 31) do not appear to belocated well with respect to fire locations and airflows.

RESPONSE: The District located the detectors relative to.the con-centration of fire loadings in the area. The bases forlocating the detectors as shown on Drawing No.13007-SK-31of the analysis is as follows:

a.) The two (2) photoelectric detectors in the ceilingat the south end of the intake structure between -trusses 101 and 102 are located above the major con-centration of the fire loading, such as, exposedcables (i.e. , cable trays), motor control centers'

and the electric fire pump.

b.) The two (2) photoelectric detectors in the. ceilingat the north end of the intake structure between-trusses 105 and 106 are located above the dieselfire pump, which is the only major fire loading inthe area.

c.) The open area between the two. (2) sets of detectors,that is between trusses 102 and 105, contains nosignificant fire loadings. This area consistsprimarily of the travelling water screens.

Thus, the District considers the detector location acceptable as proposed.

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4.) QUESTION:'The type, number, and location of detectors above theoperating level (1045'-0") of the containment should

''.. be determined on the basis of ceiling area and height.Also, other fire areas in containment should be re-evaluated with reference to floor gratings and resultantfire plume passage through the floor grating and resultantfire detection capability.

RESPONSE: Since the conference call with the flRC on May 23,1979, theDistrict's engineers have made a containment entry and .completed a detailed field inspection determining exactlocations of the detectors with respect to beams, gratingand fire loadings. Attached drawings 11405-S-18 and 11405-S-19 have been highlighted to illustrate all the pertinentin fromation.

For purposes of clarity and discussion the followingdescription of each level is provided.

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a.) _ As illustrated on District's Drawing 11405-S-18, thirteen(13) high voltage Pyrotronics detectors are located onthe bottom face of the beam at floor elevation 1013'-0".The detectors are located in the immediate area of thes

fire loadings, between the fire loadings (i.e. cabletrays) and the grating. Any fire generated would bedetected, since the detectors are in the path of theplume,

b.) As illustrated on District's Drawing 11405-S-19, aI similar arrangement exists as delineated above. Again,

thirteen (13) detectors are located on the bottomface of the beam at floor elevatioa 1045'-0". Inaddition, three (3) detectors are located below apartial landing at elevation 1060'-0". All thedetectors are located in the immediate area of the,

fire loadings providing adequate coverage.

c.) As illustrated on District's Drawing 11405-S-19 andPyrotronics Drawing EK-3070, Sheet 1, one (1) flamedetector and one (1) ionization detector are located!

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in the cavity above each main coolant pump. Thiscombination of detectors provide optimum protectioncoverage against a lube oil fire which is' the ma.jorfire loading in this area.

d.) Further fire detection coverage is obtained viaeight (8) duct ' detectors located throughout thecontainment HVAC system as illustrated on Pyro-

~ tronics Drawing EK-3070, Sheet 1.

! Thus, the District considers that the existing fire detection system -in the containment is. acceptable as delineated above, since all of the

i fire-loadings ~are below the operating level . (1045'-0"), which have. adequate detection coverage.-

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APPLICATION . PRODUCT.. ,

C aPLO C d me,i'

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INSTRUCTIONS PYROCRETEe 102350 HAM.EY pousiseALCr. Si LOUG MO 63144

These instructions are not intended to show product recommendations for specific service. They are issued as an aid in determining correct surfacepreparation, mixing instruchons, and application procedure, it is assumed that the proper product recommendations have been made. These instruc-

tions should be followed close8/ to obtain the maximum service from the materials.

Pyrocrete 102, as manufactured by Carboline Company, is a proprietary formulation of __

catalyzed mognesium oxychloride fireproofing developed to meet the U.S. Environmental EProtection Agency requirements offecting the use of asbestos in fireproofing materials.

Pyroc ete 102 has been tested in accordance with ASTM E-Il9 by the Factory Mutual ResearchCorporation under beam design IFC-206, and Underwriters' Lobosatories Design I -716, X-719.XEoch bog carries both the U.L. label and the FM Approval logo. Pyrocrete 102 has beenapproved by the major code bodies as a substitution for Pyrocrete f2 in U.L. Design D-717.

Consult Pagel0 for design and specific thickness requirements to provide the fire ratingsspecified.

I. SURFACE PREPARATION AND PRIMING

General: All surfaces must be cleaned free of oil or grease. Rust, glossy surfaces,loose or floking point, or similar conditions which would offect adhesion, must beproperly prepared.

2. LATHING AND STUDDING shall be required to comply with the following installationspecifications:

A. BEAM opplications in accordance with Factory Mutual Design #FC-206 requirethe use of 3.4 galvanized or pointed expanded metal loth (1.85 kg/sq.m.) tobox the beam. If applied to contour of beams, as per the Design # -717,DCarboline requires that you wrap loth around the edges and fiat surface of thebottom flange and inward toward the web about li inches (38 mm) beforeinstoMing Pyrocrete 102. On web arcos of contoured beams greater than 12-inches,see "C", Pg. 2. See details "A", "C", "D" and "E" on Page 10.

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B. COLUMN opplications in accordance with U.L. Design # -716 requires 3.4Xi'

galvanized or pointed reinforcing metal loth (1.85 kg/sq.m.) over edges and flat I

surfaces of both outer flanges. Wrap the metal loth around the Gange edge and; inward toward the web about I inches (38 mm) before installing Pyrocrete 102. !'

If boxed column is desired, in accordonce with U.L. Design X-719, wrap loth !

over edges of flanges and secure with galvanized tie wire to the steel, spanning;

both open web and flange faces with loth. The loth must be rigidly fostened to I

support Pyrocrete 102. On web areas of contoured columns greater than 12-inches, lsee "C", Pg.2. Refer to column details "B" and "D" on Page 10.

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C. TOWER SKIRTS ND FLAT SURFACES: Such as walls, ceilings and decks require-

ilie use of QL4 golvanized or pointed expanded metal lath overall, secured withapproved onchoring methods on 12 to 24-inch (30.5-61.0 cm) centers dependingon stress analysis. Electri cIly welded, pneumatic or self-topping screws or studsnny be used. On pressure vesse!e or pre-stressed steel or where welding orsparking is prohibited, use adhesive, backed anchors.

Contoured appih.stions on structural members with weiz greater than 12 :nches(30.5 cm) deep requi.? strips of loth one-third the webwidth onchored in thecenter of the web. The widih ef Als strip should be increased so that thePyrocrete 102 does not bridgeon uniothed width of greater than 12 inches (30.5 cm).Webs of over 36" (90 cm) should be fathed overall for greater support duringexpansion / contraction of the steel.

3. PRIMINC.

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A. Priming is required for all applications, and over existing points or primerswhich are not compatible with Pyrocrete 102. Some specific opplications undercontrolled low relative humidity environments nmynot require priming, and upon )request, Carboline Company will provide written recommendations in these cases.

B. Priming Recommendations:

1. On clean steel surfaces apply Carbolinee 193 Primer in accordance withCarboline's printed instructions. Pyroprime 772 may be used for interioropplications.

2. On galvanized steel surfaces use Pyroprep 773 plus Carboline 190 HB. Allgalvanized surfaces which come in contact with Pyrocrete require priming.However, galvanize metal loth does not require priming.

3. If Carbo Zince, or any other inorganic zine primer, has been applied, itmust be topcooted with Carboline 190 HB.

4 Sproyed-in place urethane foam requires Carboline Pyroprime/ Tie-Coat775 WB or Pyroprime/ Tie-Coat 774, mixed and applied in accordance withCarboline's printed instructions, prior to applying Pyrocrete 102.

C. *. mtection Adiocent Surfaces

Finished surfaces, such as pointed walls, floors, exposed ceilings, tile windowsand in place equipment shall be protected from domoge and overspray. Metalswitch boxes, junction boxes, conduits, sprinkler leads and similar units must beprimed and/or masked to protect from overspray of wet Pyrocrete.

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A Miscall 2neous.

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1. All non-ferrous metals, such as aluminum and copper shall be separatedfrom Pyrocrete by wrapping with tape or installation of coulking compound,or pointing with at least 15 mils of a heavy mastic type coating.

2. Stainless steel shall always be protected and pennonently separated fromi Pyrocrete 102.

3. Wood must be sealed before securing expanded metal loth over it andapplying Pyrocrete 102.

4. EQUIPMENT

A. MIXING EQUIPMENT:.

Use a heavy-duty morter mixer with rubber tipped blades of sufficient capacityto handle the number of kits to be mixed simultaneously. The most efficientmixing action is obtained when mixer is filled to appmximately one-halfcapacity. Each 100 pound (45.36 kg) kit of Pyrocrete 102 yields 2 cu. ft.(.057 cu.m.) o,f mixed material or opproximately 15 gallons (56.78 liters)of mixed material.

Typical MixersEssick Model 66Goldblott Model 07-700-E3Muller Model 110Thomsen - Model 110 or equivalents

P. APPLICATION EQUIPMENT: Installation con be mode either by trowel or5Proy.

l. Trowels: Standard plasterer's trowels or swimming pool trowels have beensuccessfully used with Pyrocrete 102. Selection of hols should be left upto the individual craftsmen.

2. Pumps: Information on suitable pumps is listed below. Other pumps withsimilar chorocteristics may be used at contractors' discretion. Outputsare listed only as o guide and is not a guarantee that these outputs conhobtained., Temperature, hose size, mixing water, gun type, etc. willoffect pump output. Consult Carboline Technical Service for specificdetails.

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Mar. 79 Replaces Nov. 78

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Mfg. & (a)* (b)** (c)* * i

Model Glover Graco 5:1 Graco 10:1 ,

-. Stallion or Bulldog President

"Pyrocreter"-- -

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Pump Screw Wyno Piston Piston

(2L3 or 2L4)

Power Gas or Comp. Comp. |

Electric Air . Air

Wximum I-5 gpm 4.6 gpm 1.7 gpmOutput 3 . 79-18 . 9 17 liters / min. 6.4 liters / min.

liters / min..

Wximum'

TheoreticalOutput 4-15 18 7Kit /hr.

(a) Rubber stator, chromed steel rotor.Gasoline powered pumps require insulation between hopper andengine to prevent overheating material in hopper.. I

*Other manufacturers include Essick (FM-9) & (FM-5E), Muller(AG-4), and Goldblatt Supertex (2L3) or (2L4), Strong knufac-turing Company, Inc. (Spray-Mate).

(b &c) Chromed piston, cylinder and check volves. For pump modifico-tion to handle Pyrocrete, consult Carboline Technical ServiceDepartment.

**Other manufacturers are acceptable with proper equipmentmodifications.

3. Compressor: Air volume and pressures required depend on equipment used.For air-operated pumps air supply must provided minimum output 75 cfm(2124 liters / min.) at 100 psi (6.8 atmg). For Rotor-Stator pumps withelectric or gas motors, air supply must be at least 22 cfm (623 liters / min.)

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ot 100 psi (6.8 atmg). Wny Rotor Stator pumps come equipped with- smaller compressors and will require a supplementary compressor to provide

adequate material break-up or else ordered with the larger compressor.

4. %terial Line: Minimum I inch (25.4 mm) 1.D. hose is recommendedFor hose over 50 feet (15 meters) in length, li inch (38 mm) 1.D. isrecommended. A 10' (3 meters) length of 3/4" (19 mm) 1.D. hose maybe added at the gun to facilitate ease of handling.

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,Pyrocrete 102 Page 5'

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Air Line: Use 3/8' (9.5 mm) or la (12.7 mm) 1.D. line from gun to.

compressor to take 100 psi (6.8 atmg).

5. Guns: Plasterer's pole gun or heavy duty mastic spray guns listedbelow are recommended. Consult Carboline Technical Service forspecific modifications.

Model Fluid Tip Air CopBinks T 47 3/8 and 3/8F

49 V2

Graco 204-000 167-331 160-658

Speeflo 701 3/8" (9.5 mm) 3/8" (9.5 mm).

Plasterer's Gun N/A 3/8" - 1/2" N/A(9.5 mm) - (12.7 mm)

6. Miscellaneous: Trowels, brushes, short nop' rollers, etc. may be required.A hopper with minimum 2 inch (50 mm) bottom outlet will be needed foruse with air motor pumps. . Hong pump outside hopper and rig bottom outletto feed into bottom of pump shaft.

5. MIXING

Dust from the mixing operation may be contained by erecting a polyethylane wind=

shield ground mixer.i

MIX IN A VENTILATED AREA

Woor a 3M Respirator / Dust Mosk (08710) Approval No. TC-2|C-132 or its equivalentwhen adding Pyrocrete Crystal component to water (Step 2 above) and when addingPyrocrete Powder to the solution. |

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A 100 pound (45.36 kg) kit of Pyrocrete 102 consists of one small bog of crystals ando larger bog of powder. Mix as follows:

A. Into the mixer place 7 * 4 gallons (28.4 * 2 liters)of cool, potable water foreach 100 pound (45.3 kg) kit to be mixed. Start the mixer and add one bog ofcrystals for each kit to be mixed. Mix for at least 3 minutes, making sure allcrystals are dissolved. Pot life con be lengthened by using cooler water andmixing in shaded areas. Storage of material in a shaded area to keep powderand crystal cooler con also lengthen pot life.

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8. With the mix:r still running, S-L-O-W-L-Y add one bog of powder to crystal.

solution for each kit to be mixed. After all powder is added, continue mixingfor 5-10 minutes until o homogeneous, mortar-like consistency is obtained. The -

iopplicator should stort with 7f gallons of water (28.4 liters)and adjust the levelfor differing conditions and odd no more water than needed to obtain good sprayand film build chorocteristics. Total water MUST NOT exceed 8 gallons (30.5liters) per 100 pound (43 kg) kit.

,

NOTE: The pot life of Pyrocrete 102 is 2 hours at 75'F (24*C) or I hour at95'F (35'C). Do not mix more than con be opplied within the pot life.Pyrocrete 102 should not be retempered, trowelled or re-used after stortingto set. Clean mixer with water every 2 hours to prevent set material fromcontaminating fresh material. Consult Carboline Technical Service for opplico-tions of Pyrocrete 102 at higher temperatures. Exterior applications con betrade at temperature as low as 35'F (2*C).

,

CAUTION: Never store freshly mixed Pyrocrete to be discorded in sealedmetal containers. Discard unused material in shipping bogs or cardboardboxes. In sealed containers Pyrocrete 102 builds'up pressure os it sets.

6. APPLICATION

A. Application and Cure Conditions: -

Surface orAmbient Temp. Relative HumidityMin. Max. Min. Max.

Interior or 20*F 95'F 0% 90%sheltered (-6.7aC) (35'C)

Exterior 35*F 95'F 0% 90 %(2 *C) (35'C)

Pyrocrete 102 may be opplied by trowel or spray to thickness required to obtain !

specified fire roting. Apply material promptly after mixing and continue untilall mixed material is used. When stopping work ciways stop at a naturalbreak such as on inside corner or screed. When resuming work after a stoppage,the adjacent surface should be damp or dampened with water mist. Do notfeather Pyrocrete 102 into cured m 'terial. Apply entire thickness in one mono-lithic coat. Adjust air volume anc pressure to assure maximum breakup ofmaterial flow for an attractive spray-texture finish.

B. Trowel Application or Finishing:

1. In some cases a sprayed finish will be acceptable. Normally, a sprayedfinish con be smoothed with a dampened whitewash brush, short-naproller, steel trowel or screed if required to meet a finish specification.

L ,,

-_ _-_ _ _ _ _ _ _ _ _ _ _ _ _ _ .

. ..,

,

.; Pyrocreh 102 poge 7.

Complete the smoothing or finishing operation within the pot life of the-

mixture. Smoothing the sprayed finish is especially recommended toassure proper II!m coverage where the Pyrocrate installation is to betopcooted. Allowir.g the wet Pyrocrete to set 1-2 hours prior to finishingyields o more easily wwked and finished surfoce. Hawk and steel trowelapplication is to be,used on Pyrocrete projects requiring a very smoothsurface. See Page 11 for details of t'ie screed technique used for aidingsmooth applications.

2. A smooth, level finish con be obtained by boxing with metal loth, using .plastic nose corner beads to form straight, sharp comers, and as a screedand depth gauge. If standard galvanized corner beads are used, the cornerbead must be prirned with Carbomastice 15 offer installation of thePyrocrete to replace the golvanized scraped off by the trowels during.opplication. See detail drawing "D" on Page 10. See detail ."G" onPage 11 for box design without corner b_ ads.

C. Spray Applicat on: Before starting, lubricate the equipment by pumping water '

through tne pump and material hose. Start pump and odiust atomizing air togive proper breakup of Pyrocrete 102. Hold gun 12 (304 ram) to 18 inches |.(457 mm) from surface. Cover edges first. Avoid excessive buildup in inside

'

Smooth surface of Pyrocrete ofter spray is recommended for oestheticcorners.reasons.

Keep mixer, pur ,., and material in shode to prolong pot life.

lWhen stopping for lunch and at day's end, cleon mixer and pump thoroughly

,

with fresh water. Pump a sponge with water back flush through material hose, {-

offer removing the gun, to cleon out all residual Pyrocrete. In worm weather, |

flush clean water through the equipment every 2 hours to prevent residual|

material from setting up. When preparing pump for storage follow equipment '

manufacturer's recommendation.

D. Curing: Like all water based materials, No rcpid drying will interfere with !

proper hydration of Pyrocrete 102. In low humidity, high temperature or direct |sun or wind, keep Pyrocrete surface damp for at least 6 hours. Apply a fine mist |

water spray as needed, or wrap in polyethylene sheets. '

Fresh Pyrocrete 102 must be protected from soaking rain or running water for24 hours at 70*F (21*C) to prevent leaching of catalyst.

E. Miscellaneous:.

1. If multiple coat opplicot' as of Pyrocrete are equired, apply oil cootsof material within 6-8 hours.

2. At no time shall Pyrocrete be used as a wash coat nor opplied at a thicknessless than A inch..

Mar. 79 Replaces Nov. 78|

.

. ... . . . .

'

: @a,44012 Page 8.

. . . . . . .-

CAUTION: Do noEMort work if ambient or surface temperature 's expected to dIEp below .

'

20'F (:6*C) for a period of 8 hours following _opplication. -

.

_ n. = =- .

E. TopcoatimpePyrocrete 102 must be protected from excessive humidity, weatherand chemical fume exposures by topcoating. Unless otherwise specified, topcoat...

with Pyrocote 787 or Pyrocote Elastomer 788 Aluminuni. The Pyrocrete 102 mustbe cleo#erddry when topcooted. Topcoat cannot be applied at surface tempero-tures below.40*F (4*C).

li The surface hardness should be a minimum of Short D "55", os measuredwith a Durometer, prior to topcoating. Normally minimum drying timebefore applying protective or color topcoating is 5 days at 70*F (21*C).l.ess time is required at hotter temperatures and more at lower temperatures.The Pyrocrete surface must be dry and shall not have been ruined on for48 hours prior to topcoating.

2. Do not opply Pyrocrete 102 on exterior locations if weather or twnperature !._. below 40*F (4*C) will prevent topcoating for.30 days.,

F. Coulking: On exterior or unprotected applications, coulk joints and seems,hangers and braces with Carboline Acrilost 570 or equivalent to prevent water -seeping behind Pyrocrete 102. Design should allow for adequate drainoge. SeeDetail "E" and "F", Page 10. Do not use coulking cornpounds that are notcompatible with Pyrocrete 102. '

G. Clean Up: Wet Pyrocrete overspray or dripping must always be cleaned up withsoopy or fresh water before it sets.and/or scroping to remove. _

Cured Pyrocrete overspray may require chipping

H. Storage: All containers must be completely sealed and stored under waterproofcover and off the ground. Storage in shaded, cool areas will yield cooler materialand help lengthen pot life of mixed material. Nominoi shelf life is I year.Pyrocrete powder which has been exposed to dompness and allowed to becomelumpy shall be discarded.

STORAGE CONDITIONS

Temperature telative Humidity j-20 to 150*F Max. 0% Min to 90% Max. J(-29 to o6*C) Max. |

7. SAFE 1Y

A. Do not breathe dust Pyrocrete 102 is coustic and will irritate mucous membranes.Use on opproved breathing mask while mixing Pyrocrete 102.

.

Mar. 79 Replaces Nov. 78

i

__

.-'

, Pyrocrete 102 Page 9*

. . .

. .. .3

- B. For eye contact, flush eyes with plenty of clean water and rinse with boric,,

acid eyewash. Goggles or safety glasses are always recommended..

lC. Wash off skin with clean water to prevent irritation.

D. MIX IN A VENTILATED AREA!

Wear a 3M Respirator / Dust Mask (08710) Approval No. TC-2|C-132 or itsequivalent when adding Pyrocrete Crystal component to water (Step 2 above)and when adding Pyrocrete Powder to the solution (Step 3 above).

.

Mar. 79 ReplOces Nov. 78

To the best of our knowledge the technical data contained herein are true and accurate at the caste of issuance and are subject to changewithout preer notoce. User must contact Carbolene to verify correctness tWore spec 6fying or erwme. No guerentes of accuracy is given orimpiled. We guarantee our products to conform to Carbolitio quality control. We assume no re : 1'Isty for coverage, performance or iniursesroeutting from use. LiebiHty, if any, is lan6ted to roolecament of products. Proces and cost data le shown, are subsect to change without or6ernot6ce. NO OTHE R WARR ANTY OR GUARANTE E OF ANY KIND 15 MADE SY THE SE LLER, EXPRESS OR IMPLIED, STATUTORY,BY OPERATION OR LAW, OR OTHERWISE, INCLUDING MERCH ANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

.

e

|

4

|-

|\

i!

,

_,I

~ '

Page 10~

i~

APPLICATION DETAILS FOR PYR0 CRETE 102.

BOXED BEAM COLUMN DESIGN

@ BASED ON FACTORY MUTUALDESIGN FC-206LOADED BEAM ASSEMBLY BOCA APPROVED

SERIAL NO. 23188' "

COLUMN ASSEMBLIES~ . . .. N.'.IN.9. A . . .. 8

*.

.[- u. L. Dess n X.716 U. L. Demon X 719** *

e,

Pyrocrete 102.,,e c. s

;% st-i noor om* g_ ., , h5 4 9 Concrete ,

M__; N A (b - .

Thickness of coverage Beam Roteng '

3/8" (1.0 cm) 4 hrs. Thickness Rating'

M- -

z 6" ('14 ) Hrs'.t.: . Pyrocrete 102 7/8" (2.2 cm) 3 Hrs.g. .

..- -

Tie were 1-3/16" (3.o em) 4 Hrs.

[ I f(hBeem Firring '5 cc ' "gS ".,

Cleo,'actionall % ? -

FLOOR / CEILING / BEAM ASSEMBLYWITH C NER DS

DESIGN 0 717 * ~ '-

. . c. ' ... j Qi stees seem .,

I' '

Steel Member,y G) Pyrocrete e2

| {G DECK Assembly- * | gd @ met.: a.:.-

.f . j,

d I

M. "hOptional Plastic Noserh.ekness Rai.n,

.\ Corner Bead "s %

In'.

'*'sfnedune

' Pyrocrete'1/2" (1.3 cm) on 3 Hrs. Restrained jdeck Assembly /9/16"(1.4 cm) g

;on beam* Code approved substitution of Pyrocrete 102 re-

,

queres metat fath reinforcement on lower flange ofbeam as shown.

, , g ,n ,, g, ,,

@ TYPICt.u BEAM DETAll TYPICAL TOWER SKIRTON PIPE RACK OR WALL DETAll

Caulking caulking

k b ,, v.kY, + Cladding'

es w!6

f.gt Insulat.a .,

[:Steel N D kI \ '

IUm-df 4O 2'e"#f;,"; !@Y Weatherproof'5 ."9

ii i is lef t unprotected. 'I. A h. * ' '"

,

-4 |' Pyrocrete Mesh Steel - ~ ~. 9. i Pyrocrete*'

f x -..

s-

s~

Metallath.i-

<_ J-

Metal lath [ .|- Attached with studs'

over edge and bottom D*. ? Or lnsulation Clips24, (.31 meters) On Center

, . .

of lower flange only, s. . . .

"" "# "' 'Mar. 79 ReploCes June 78

_ ;

A |.,'

.Py'r.ocrcta 102' '

"'" "SCREED METHOD DETAILS

'

.

K CONTOUR APPLICATION

Spacer blocks (C) cut to required thickness andA held in place. InstaN screeds (B), precut to twice

required thickness plus flange thickness and cen-@ tered on spacer blocks, held in place with clamps.

Apply Pyrocrete by spray or trowel and strike offexcess Pyrocrete and apply this to web area. .

/Remove screeds and spacer blocks after approxi-mately 8 - 12 hours and fill void left by spacer .

blocks with Pyrocrete.A - Structural MembersB - Wood Screeds Do not overwork the Pyrocrete.C - Wood Spacer Block

,

D - Pyrocrete

NOTE: Lath may be required

| on Flange Faces and webs.

,

'|

D

x x

BOXED APPLICATION

Precut wood screeds (8) and use spacer blocks ifA required to obtain the required thickness of

Pyrocrete.

C Clamp screeds on flange face only. Apply scratchcoat by spray or trowel to web area first.,

Continue full appliastion of Pyrocrete to flangefaces before returning to web area. Entire thickness

Q** Q of Pyrocrete must be made within the same day.~*~

\ ! Do not overwork the Pyrocrete.

A - Structural MemberB - Wood Screeds

. C - Metal LathD - Pyrocrete

-- _ . _ . - _ _

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Spraying PYROCRETE with plasterer's spray gun permits PYROCRETE spray-texture finish can be readily smoothedscsy access to parking garage beams without need for scaf- by rolling with a smooth paint roller. striking with a trowelfolding. Nozzles may be varied to provide wide range of or screed. wiping wish a teflon strip or any similar mechan-spray patterns. Same gun is available with short handle to ical finishing technispee where a smooth finish is specified. 1facilitate working in close quarters. '

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PYROCRETE powder is fed into the mixing solution to make PYROCRETE " spreads like butter". Experienced troweli

a stiff mortar-type batter. To speed production. the catalyz- men can make quick. clean installations. Materialdoes noting mixing water can be prepared in advance in bulk and shrink when setting. so applications as heavy as 1%" (38drawn off as required. Mixer must be cleaned out regularly mm) can be installed in a single stage. Lath and corner beads

,

I

to avoid s antamination from " set-up" material which can can be quickly and easily installed. as desired, to frame, clog spray guns. structual members. -

1

(See inset)

l

|1

- -

_ _ _ . ,m. . . - ,- -.- - _. .

4,-

(I,";m*T. .'~

..

July 20, 19'76

. b.. .

car bCIIne'. - 4 -

.-

.: .. 1

THERMAL TRANSMISSION OF PYROCRETE AT VARYING THICKNESSES.

.

FURPOSE: To experimentally dete wine the time the back side temper-f,ature of Pyrocrete reached 250*F above ambient, when applied ,

at varying thicknesses, and exposed to the standard ASTM.E-119 time / temperature.,

, .

REFERENCE: Johns-Manville Research Center .

Denver, Coloradoi

-.

CONCLUSION: The following thicknesses of Pyrocrete reached 250*F above '

ambient, at the time periods shown:.. .

1. 1/4" 12 to 13 minutes -.

2. 1/2" 15 minutes *

3. 1" 46 minutes '-

4. 2" 195 minutes -

(See Figure 1 - Best Fit Curve.)

PROCEDURE: 1. System' "

A. Steel Plate 2' x 2' (16 gauge'),

B. 3.4 galvanired metal lath spot welded to the '

steel panel..

C. Pyrocrete 102 'at varying thicknessesi,

.

2. Application -

,

'

', A. Pyrocrete spray applied at the following thick-nesses:. 1/4", 1/2", 1" and 2". Screeds wereused to obtain exact thicknesses.'

3. Cure

Pyrocrete 30 days ambient laboratory. |

4. Tests ''

A..

Expose Pyrocrete to standard ASTM E-119 time / itemperature curve.

t

B. Measure the temperature of the uMxposed unin- .

sulated back side of the steel panel with four ,'

thermocouples. Three thermocouples to bepositioned so that an overall' temperature is

'

obtained, and insulated with a 2" asbestos disc.7The remaining thermocouple to be uninsulated and r.. positioned in the center of the panel.-

I. g-

.

1,

, _ _ - -

.- ,e e - 2.. .o .

'- *.

. ' , . .i - July 20,1970: ) ..'.

. --

. o1 5. R""ultst - -*s

4 p.'s' r-- x & - n if [-

'

1 TABI.E I 3' i (||- --

.: ? ?.

1/4 Inch Thick Pyrocrate, , , , _ ,

-

ae (Sample) -

.

~.

. .

. -.

,

Average Tem- Temperature (*F) Furnace .

Time parature ('F) of Uninsulated Temperature(Minutes) 3 Thermocouples Thermocouple *F

.

..

5 205 200' 975'

bs10 ; 215 210 1375- -

.. a ,. .

~. *

J

16 325 350 1430,

.

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TABLE II ! ~-,

. - ?..

;p..

.1/2 Inch Thick Pyrocrete. . -

. .

.,

_. ..

(Sample)t

- - . . . . . . e.. .

~...

Average Tem- Temperature (*F) FurnaceTime ~ perature (*F) of Uninsulated Temperature .

(Minutes) 3 Thermocouples Tnermocouple 'F.

'

.

5 215 210.- 970 --

.

.Cr - 10 265~. .

1360 -. ~.*1.

. .

<

%' '

15 325 325 1420-.

.

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'

I.' TABLE III - ''

* *

.c,

e' - -. ,

b 1 Inch Thick Pyrocrete |

*

(Sample) * J9 . .

.

-. .. .

. -. ,

Average Tem- Temperature (*F) FurnaceTime parature (*F) of Uninsulated Temperature -

(Minutes) 3 Thermocouples Thermocouple 'T - |1

1*5 100 110.. ,1010 ;

.

t# ~

15 a 210 200 1420 .

~-

... .

*

30 230 230 - 1570*

1

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40 * 260 260 1610:

,

47 325 325 1650 !d

.

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50 ,p 333 345 1660m. .. .

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TABLE IV-'

,- .-.

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2 Inch Thick Pyrocrete-.

-. -(Sample)*

. gf .

Average Tem- Temperature (*F) . Furnace~

''

Time perature"(*F) of . Uninsulated Temperature* * * '

(Minutes) 3 Thermocouples Thermocouple 'F.

. 15 100 100 - 1370 2'

..

*

, , - 20 120 110 1490.

k

*f. !-

|.

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o25 150 140 .i- s.540.

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,

33' 200 180 1630'

-

.

-

|40 210 180 1620--

h50 210 180 1670,

._

,h60 210 180 1710

*

.,,

.

75 205'

180 ', 1740! 6,

'

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90 205 180 1 1780 'a-,

p..

I>105 205 180 . 1850 [r

,

d120 205 180 1860 *

C,' 150 220 190 1880

P

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4

' 180 270 '250 1900.

2 1

200 316 280 1930'

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a. 205 325 280 1930 4P.wl.

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TIME-MINUTES TO END POINT .I!.250*F RISE ABOVE AMBIENT (325'F) !

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July 20,197 3, -

$1$cUssIonh0'tEgsULTs: Th2 racults of tha 1/4" and 1/2" thickn2co cf Pyracre to cppa trad ts

have performed equivalently. In the panel preparation, screeds were'*

used so that the exact thickness was obtained. 'There is no technicalb reason for the similar results, therefore I anst consider these asexperimental error. ,-,

P .

The remaining test specimens of 1" and'2" resulted in accepta'ble - -

data.-- -

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Plotting the end point temperatures of 325'F versus time, a best fit -

curve was drawn that shows the finish rating resistance at varyingthicknesses. ~

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The temperatures of the three uninsulated thermocouples, did not-.

f.g | differ significantly when compared to the uninsulated thermocouple.- ,

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Chris F. Maeda14n.

1Fireproofing Group Leaderi

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