Durasteel brochure v24

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Promat DURASTEEL®
High Performance Barrier & Ceiling Systems

Durasteel Brochure.indd 1 28/10/08 15:32:53

Promat DURASTEEL® High Performance Systems

Contents

What is Promat DURASTEEL®? 3

Technical Data & Construction Details 4

Technical Services & System Installation 5

Regulatory Reform (Fire Safety) Order 2005 5

System Performance, Tests and Approvals 6

System Key Features and Beneﬁts 8

Promat DURASTEEL® Range 8

Low Radiation Fire Wall 9

Radiation Characteristics 9

Protected Zones, Spandrel Panels, Smoke Screens 10

Valve Protection Enclosures 10
Insulated Fire Wall Systems 12

FIREBLAST® Wall Systems 12

System Applications 13

Speciﬁcation Details 16

Case Studies 29

Licensee Testimonials 31

2



WHAT IS Promat DURASTEEL®?
Promat DURASTEEL® is a composite panel of fibre reinforced cement mechanically
bonded to punched steel sheets on both outer surfaces. It is classed as ‘non-
combustible’ to BS 476: Part 4: 1970 and A1 to Clause 10 of BS EN 13501-1:2002.
Promat DURASTEEL® is both highly impact and moisture resistant.

Promat DURASTEEL® has been developed and supported through rigorous testing for
use in barriers, door and ceiling applications, with a wide range of specifications available.

Promat DURASTEEL® systems combine lightness, strength, impact, blast resistance
and durability with exceptional fire resistance. In addition, Promat DURASTEEL® can also
withstand the effects of firefighters’ hoses.

Promat DURASTEEL® systems have been used successfully across the industry for many
years, including large rail, metro and airport projects, as well as military developments and ABOUT Promat UK
commercial, pharmaceutical and petrochemical facilities. Promat UK Limited is a market leader
in passive fire protection and high
temperature insulation, with a fire protection
Promat has developed DURASTEEL® to provide an effective blast resistant solution to
range that offers a unique combination
constructions in a wide range of industrial applications, including power generation and
of product benefits: exceptional strength,
anti-terrorist installations. impact and moisture resistance, ease of
working, installation and safety in use.
HIGH PERFORMANCE SYSTEMS
Promat DURASTEEL® walls and partitions can be designed and installed in various layout Promat UK Limited is a subsidiary of
and framing options to meet a multitude of needs. In today’s construction markets the need Promat International, which has sales
offices, factories and workshops worldwide.
for systems which can perform multi-functional roles, whilst capable of allowing for fast track
and cost effective installation, are of prime importance.
Promat DURASTEEL® fire and impact
resistant systems provide a cost
The Promat DURASTEEL® partition and wall systems can easily fulfil all of these roles. Promat effective fast track solution for the
DURASTEEL® walls have resistance to extreme impact, before, during and after exposure to compartmentation of large warehouses and
fire. This ensures that under use, they suffer no damage from the burden of every day exposure fire resistant enclosures, rooms, ceilings,
within, for instance, warehouse situations. Under fire conditions they protect and maintain cable trunking and similar applications.
compartmentation and after a fire they ensure a building remains secure until remedial work can
Promat DURASTEEL® systems can be
be undertaken.
fitted with a range of compatible personnel
doors, sliding and guillotine doors, roller
Promat DURASTEEL® systems can be installed quickly; on most occasions they have no shutters and access hatches to provide up
requirement for additional foundations or other special construction works. Installation is a “dry” to 240 minutes fire resistance.
trade, thus there is no disruption of other trades working in the same areas, allowing faster
project completion.

Promat DURASTEEL® systems can offer both integrity only or integrity and insulation.
Walls can be designed for high blast resistance and meet most of the generally
recognised fire curves, including cellulosic and hydrocarbon.

Promat DURASTEEL® systems combine extremely high levels of fire, impact and water
resistance. They are proven to withstand the most demanding environments, temperature
extremes, hostile elements and can resist high thermal shock, such as high pressure
water hoses.

Promat DURASTEEL® partition and wall systems can be used in applications such as
separation of hazardous areas, shielding for valve actuators, protection of escape routes and
tunnels, construction of refuge areas, compartmentation within buildings and storage areas
for hazardous goods or equipment protection.

3



Typical Mechanical Properties

Flexural strength Frupture 6mm Average, dry N/mm2 109
Flexural strength Frupture 9.5mm Average, dry N/mm 2
84
Modulus of elasticity E 6mm Average, dry N/mm2 55000
Modulus of elasticity E 9.5mm Average, dry N/mm 2
40000

General Technical data

Material class Non-combustible
Surface spread of flame Class 1
Building Regulations classification Class 0
Alkalinity (approximately) pH (core) 10-13
Thermal conductance (approximately) at 20°C W/m2K 60 (9.5mm)
Coefficient of expansion (20-100°C) m/mK 15 x 10-6 (9.5mm)
Nominal moisture content (air-dried) % 6
Moisture movement (ambient-saturated) % –
Thickness tolerance of standard boards +1.0 to -1.0 (9.5mm)
Length x Width tolerance of standard boards mm ±2.0

Board Format Data

Thickness Length x Width Approximate Weight
(mm) (mm) (Kg/m2)
Dry With approx.
6% moisture
6 2500 x 1200 15.9 16.8
9.5 2000 x 1200 19.8 21.0
9.5 2500 x 1200 19.8 21.0

Performance Details

Specific Applications Primary Performance Fire Performance
Required (minutes)
Public and service corridors
Warehousing
Industrial buildings
E240
Impact E240, El60
Mass transit systems resistance E240, El120
Manufacturing facilities
El240
Other areas subject to
abnormally rough use
Offshore facilities
Petrochemical industry H0
Blast
Gas processing plant resistance H60
Other areas subject to H120
projectile or explosion risk

NOTE: Fire performance figures denote integrity (E) and insulation (I) performance respectively.
For details of specifications and installation details, please consult Promat Technical Services.

4



DESIGN AND TECHNICAL SERVICES
With over 100 years of combined experience, our dedicated technical and sales
support teams are available to provide information and assistance to help in the
design and installation of Promat DURASTEEL® systems.

SYSTEM INSTALLATION
After a site survey, installers will provide fully designed working drawings. Promat will
supply the fire resisting sheets, doors and penetration seals, which provides a single source
and responsibility.

All elements are tested as a combined system to ensure compatibility, with one source of
warranty. Access panels for maintenance or fire stopping of penetrations through the barrier
can be included in the system estimate.

Promat DURASTEEL® systems are installed by experienced, licensed installers. Once the work
is complete, the system undergoes a thorough check before the installation is issued with a
Certificate of Conformity.

Our licensed installers are all assessed under the FIRAS third party accreditation scheme.

REGULATORY REFORM (FIRE SAFETY) ORDER 2005 (RRFSO)
Fire safety law changed in October 2006. The emphasis of the new law is prevention of fires
and reduction of risk, and makes it the property owner’s responsibility to ensure the safety of
everyone who uses their premises and the immediate vicinity.

The Department for Communities and Local Government (DCLG) have produced a set of
guides to advise the responsible person how to comply to the fire safety law, help them to
conduct a fire risk assessment and identify general fire precautions that will need to be put in
place.

Failure to meet the requirements of these new regulations could lead to prosecution, which
could then result in hefty fines or even imprisonment. The Order replaces any previous fire
legislation. Any fire certificates issued under the Fire Precautions Act 1997 ceased to have effect
from 1st October 2006.

Promat provides a free advice service to help parties within the building industry to make the
right choices in fire safety. Promat’s technical department monitors any changes and tests
systems in order to offer solutions to help comply with fire safety legislation.

5



SYSTEM PERFORMANCE

Type Building & Construction Offshore Constructions

Single-skin E60, E120, E240 or E360 Marine Classification A0
Constructions (A and B class), H0
Double-skin EI 60, EI 90, EI 120, EI 180 Marine Classification A60
Constructions or EI 240 for standard fire tests
H60 and H120 ratings for
hydrocarbon fire tests.
Special Promat DURASTEEL® has been designed and installed in many purpose
Constructions built fire walls, which provide special performance characteristics beyond
fire resistance. All structures can be independently assessed to ensure
the required performance is achieved.

SYSTEM TESTS AND APPROVALS
Promat DURASTEEL® systems have been tested extensively in the UK to comply to all relevant
parts of BS 476, as well as many internationally recognised approvals such as: Factory Mutual
(FM), Underwriters Laboratories (UL), Underwriters Laboratories Canada (ULC), Det Norske
Veritas (DNV), Lloyds Register of Shipping (LRS), Zulassung, EDF and LUL. The systems have
also achieved the stringent Certifire approvals.

Over £2.5M has been spent on tests, assessments and approvals to comply with many
insurance specific requirements, both in the UK and overseas.

Promat has completed investigative programmes at our facilities in Belgium and the UK.
DURASTEEL® is manufactured in accordance with independently accredited BS EN ISO 9001
quality and ISO 14001 environmental management systems.
The picture right shows a Promat DURASTEEL®
wall undergoing impact following a fire test.
The picture above shows a concrete block
wall undergoing similar testing.

6



The picture above shows a Promat DURASTEEL® wall being ﬁre tested to E240.
Below are examples of Promat DURASTEEL® UK and International certiﬁcation.

7



KEY FEATURES: KEY BENEFITS
● Comprehensive technical expertise ● Insurance industry recognition
• Up to EI 240 and E 360
● Certifire accredited systems ● System fully fire tested to conform
fire rating
● FIRAS accredited and fully qualified to new RR(FS)O standards
• Impact resistant licensed installers ● Tested with a range of service
• Unaffected by water ● Guaranteed system with full certificate penetrations and fire doors
of conformity ● No maintenance ‘fit and forget’ system
• Non-combustible ● Tested to comply to UK and ● Over 40 years service life
• Minimal smoke or toxic international standards ● High speed of installation
gas in a fire

• Slim, space-saving profile
SYSTEMS AVAILABLE
• Lightweight, no foundations Some common partition systems constructed from Promat DURASTEEL® are shown on the
following pages. When considering the design of walls, it is essential to consider the section
• Easily relocatable
size of the steel framing in conjunction with the wind loading factors, expansion allowance,
• Hose-stream resistant together with the height and span of the wall, to ensure that under both ambient and fire
• Mechanical or seismic conditions, the wall will provide the necessary design performance. The basic framing system
vibration resistant comprises of lightweight steel sections, with a nominal 3mm thickness, dependant on the other
design factors etc. All framing is either bolted, screwed or welded into position, dependant on
• Suitable for retro-installation
location, performance parameters and design requirements.
• Low sound transmission
Where a cold smoke seal is required, the boards must be bedded on PROMASEAL® fire rated
• Good acoustic insulation
performance silicone or PROMASEAL® Intumescent mastic. For demountable wall systems, to ensure
sealants do not act as adhesives, a cold smoke seal composed of a 2mm thick strip of Promat
PL Intumescent strip can be applied. For integrity only systems, Promat DURASTEEL® walls
have been tested with the framework on both the exposed and unexposed face to fire, in
order to show that the frame can be exposed without detriment to the fire performance of the
system.

The framing for the Promat DURASTEEL® wall systems must be securely fixed back to a
substrate (concrete, masonry or steel) that has an equal or better fire performance than
the designed wall. All fixings must be non-combustible, and must be listed in the approval
documents. Expansion bolts used to fix framework should be steel, not aluminium or plastic.

8



LOW RADIATION FIRE WALL
Low radiation fire wall for constructions that require a high degree of stability, integrity
and insulation as measured upon the unexposed surface of the wall is not critical, but
where heat radiation from exposed to unexposed face could be of importance. Promat
DURASTEEL® low heat radiation walls offer a lightweight construction, which is very narrow
across its thickness.

Used in conjunction with the Promat DURASTEEL® pallet racking fire barrier system,
this wall offers increased warehousing space and allows for racking to be placed practically
against the Promat DURASTEEL® wall itself.

Single layer Promat DURASTEEL® fire walls can be constructed using framing of either steel
channels, Tee sections or back to back angle sections. The type of framing system and
the dimensions of the steel sections will depend on the performance requirements of the
wall in terms of wind load, fire performance and impact resistance. In these circumstances,
Promat DURASTEEL® walls provide a bespoke solution.

RADIATION CHARACTERISTICS
Radiation levels measured during a test on a single skin 9.5mm Promat
DURASTEEL® barrier

Radiation Levels (kW/m2)

Distance from After 30 After 60 After 120 After 240
barrier (metres) minutes minutes minutes minutes
0.5 7.5 12.0 16.0 20.0
1.5 4.6 7.1 9.8 12.5
2.5 2.5 3.9 5.4 6.9

Effects of Thermal Radiation

Radiation Heat Flux (kW/m2) Observed effect
0.67 Summer sunshine in the UK
12.5 Piloted ignition of timber
29 Spontaneous ignition of timber

9



PROTECTED ZONES, SPANDREL PANELS, SMOKE SCREENS
Smoke kills more people in fires than heat, flames or structural collapse. It is therefore
recognised that occupant safety in a fire can be greatly improved by providing an
efficient smoke extraction system. Part of an engineered smoke control system may
involve the provision of smoke reservoirs, the use of smoke channelling screens and
smoke curtains.

Testing standards for smoke control equipment smoke curtains and screens shall meet
the requirements of BS 7346: Part 3: 1990, which requires the screen to withstand a
fire temperature of 600°C +/-20°C for a minimum of 30 minutes.

The Promat DURASTEEL® system has been tested to the criteria of BS 476:
Part 20, which has much higher exposure temperature requirements and it provided a
performance in excess of 240 minutes. Promat DURASTEEL® barriers can also be
used in position as horizontal “wings” (protected zones) at the head and to the sides of fire
walls, forming an added “band” of protection at the junction with other substrates (as detailed
in the FPA Design Guide Supplement 2004). This makes it exceptionally difficult for fire to
breach a roof and thus leap over the top of, or around, the fire resistant wall system.

Promat DURASTEEL® can also be used within spandrel panel systems, positioned at the end
of floor slabs in order to prevent fire bridging gaps between floor slabs and curtain
wall systems.

VALVE PROTECTION ENCLOSURES
The ability to isolate storage areas or to direct highly combustible fuels away from
a heat source through a series of protected valves is paramount in the event of fire.

When subjected to high temperatures, the plastic parts of a valve can easily be rendered
inoperative, resulting in the valve’s inability to divert or arrest flow.

Promat DURASTEEL® can offer different methods of protection for valves, dependent on
the requirement.

In certain circumstances, it may be sufficient to protect the valve with a fire resistant
shielding. In other cases, a more substantial form of protection may be required. In these
circumstances, the valve can be fully enclosed within a Promat DURASTEEL® valve actuator
box. These boxes have been designed to ensure the valve temperature cannot rise by
more than 30°C in 15 minutes, or 30°C in 30 minutes, depending on the type of Promat
DURASTEEL® system installed.

10



Promat DURASTEEL® barrier

Typical Penetration details Insulated barrier

11



INSULATED FIRE WALL
Fire walls are used in constructions where high insulation as well as stability is required during a
fire. Promat DURASTEEL® insulated fire walls are designed to prevent the passage of heat from
a fully developed fire on the exposed face. The maximum permitted temperature rise allowable
on the surface of the unexposed face is 140°C as a mean temperature over all the surface, or a
maximum temperature rise of 180°C at any one point over all the surface.

Insulated wall constructions should be used in areas where the following may occur:
● Escaping personnel or fire fighters may have bodily contact with the wall surface.
● If used as a wall lining to any escape route, for instance as an access tunnel within a factory.
● If there are any volatile chemicals or materials stored within the vicinity of the fire wall and
which may ignite at low temperatures.
● There is a need to improve compartmentation beyond simple integrity.

There are a number of methods of constructing insulated wall systems. Each option has its
own benefits. The type of system, thickness and density of the rock wool and cover strips, if
required, are all dependent on the fire and physical performance required from the system.

FIREBLAST® WALL
Designed specifically to protect personnel and equipment from the effects of explosion,
fire, impact, and the effects of smoke and fumes in hazardous environments, such as offshore
platforms, petrochemical installations, chemical plants, military establishments, civil defence
works and hazardous process plants.

Additional features of FIREBLAST® fire and blast resistant walls:
● Blast resistant, tested from 0.3 to 2 bar over pressure.
● Resistant to hydrocarbon fires, tested to H120.
● Impact resistant to 4000J after 180 minute fire test. In accordance with DIN 4102 Parts 2
and 3 requirements
● High energy absorption.
● Hose stream resistant to a 5 bar high pressure hose (ASTM E119).

Unlike many fire and blast resistant materials, Promat DURASTEEL® is non-combustible and will
withstand an explosion followed by a prolonged fire and still be unaffected by hose stream fire
fighting. Its integrity remains unimpaired, ensuring continued protection against fire, impact and
moisture as well as preventing the escape of smoke and toxic gases. Promat DURASTEEL®
systems are tested up to H120 fire rating, and the systems can be designed to suit specific
project performance requirements.

All FIREBLAST® walls are individually tailored to suit specific project performance requirements,
please consult the Promat Technical Services Department for specification and construction details.

12



SYSTEM APPLICATIONS

Promat DURASTEEL® FOR INDUSTRY
Manufacturing & Warehouse Complex
The need for effective protection of personnel,
plant, stores and property in industry is vital.
Promat DURASTEEL® is proven to contain
fire within compartments of a production area
or storage facility, thus allowing evacuation of
personnel, minimising disruption of processes
and preventing the destruction of valuable stocks.

As an indication of the effectiveness of
Promat DURASTEEL® these photographs
show a production facility before and
after a fire. The Promat DURASTEEL®
wall separating two sections of the factory
performed exactly as designed. Indeed, the
bottling plant on the unaffected side of the
barrier was operational again within 2 days
of the fire, therefore minimising the effects
of the incident as much as possible.

Promat DURASTEEL®
FOR TRANSPORTATION
INFRASTRUCTURE
Underground Rail System
Promat DURASTEEL® is lightweight,
robust and ideally suited to the
external environment of all trackside,
station and rolling stock fire protection
requirements. It is also widely used in
road and rail tunnels.

Knights of Old DURASTEEL® barrier

13



Promat DURASTEEL® FOR COMMERCE
High-Rise Office Block
Promat DURASTEEL® is the first choice fire protection
product for an impressively wide range of structures,
including high-rise offices and hotels, airports, retail
parks, leisure complexes, public buildings and
government institutions.

Promat DURASTEEL® has also undergone rigorous
testing for use in electrical plant rooms and is the
approved system for the numerous EDF installations
throughout London.

Other Promat DURASTEEL® applications may be suitable in high-rise office blocks; e.g. fire
doors, fuel storage and boiler room enclosures, ceilings above liftshafts, ceilings to fan rooms,
lift door transom panels, curtain wall fire breaks and penetration seals.

Airport
For every airport operator, one item within their mission statement is to provide for the highest
standard of safety in civil aviation and airport operation. The range of Promat DURASTEEL®
systems for airports are proven to meet or exceed the most rigorous British and International
legislative requirements.

Other Promat DURASTEEL® applications may be suitable in airports; e.g. duct splitters,
riser shafts, transformer enclosures.

14



PROMAT DURASTEEL® FOR NUCLEAR AND FOSSIL FUEL POWER STATIONS
Nuclear/Fossil Fuel Power Stations
In an industry where the concern for environmental protection, coupled with increasing
demand for electrical power, brings constant technology development in both conventional
and new approaches to energy supply, only a system such as Promat DURASTEEL® has
the flexibility to match the need for innovative solutions.

Promat DURASTEEL® is non-combustible, will withstand prolonged hydrocarbon fire,
resists hose-stream fire-fighting, is impact and moisture resistant, and does not emit
smoke or toxic gases.

Promat DURASTEEL® FOR HYDROCARBON
Offshore Oil/Gas Production Platform
The light weight and strength of Promat DURASTEEL® combine with its resistance to
hydrocarbon fire, blast, impact, water and corrosion to make Promat DURASTEEL® systems
the ideal choice for fire protection on offshore production platforms and in potentially hazardous
land-based environments.

15



PAINTING AND DECORATING SPECIFICATION DETAILS
Promat DURASTEEL® is self-finished The following pages details the specifications for the range of standard barriers, composite
in either galvanised or stainless barriers and suspended ceilings offered. If you require advice on bespoke systems please
steel and requires no decoration. contact Technical Services on 01344 381400.
If decoration is required, Promat
DURASTEEL® should be de-greased Promat DURASTEEL® STANDARD BARRIER SYSTEMS SPECIFICATION DETAILS
with a solvent based cleaning agent
Stud Channel Sizes
before any form of decoration is
applied. Seek paint manufacturers Height of Size of channel for single Size of channel for double
recommendations. partition (metres) skin uninsulated partition skin insulated partitions
(mm x mm x mm) (mm x mm x mm)
MAINTENANCE 0–6 80 x 60 x 3 80 x 60 x 3
AND CLEANING 6–9 150 x 60 x 3 150 x 60 x 3
Panels do not normally require any 9 – 12 Two 150 x 60 x 3 back to back Two 150 x 60 x 3 back to back
maintenance in use. If panels are 12 – 15 Two 175 x 60 x 3 back to back Two 200 x 60 x 3 back to back
damaged they should be replaced
For Standard barriers specification details see pages 18-19.
rather than repaired in order to
ensure fire performance Insulated Partitions
is maintained.
Fire resistance Minimum stud DURASTEEL® Rock wool infill
PROMAT DURASTEEL ® – minutes depth – mm fillets per face
SUSPENDED CEILING E240 / I120 80 1* 2 x 40mm x 140kg/m3
SPECIFICATION DETAILS E240 / I120 150 None 3 x 50mm x 80kg/m3
See pages 20-24 for suspended E240 / I240 80 2* 3 x 40mm x 140kg/m3
ceiling specifications. For self E240 / I240 150 2* 3 x 50mm x 100kg/m3
supporting ceilings please refer to *Fillets must overlap the channels by at least 20mm on both sides. For Composite barriers specification details see
the Promat Technical department pages 25-27.
on 01344 381400.
Promat DURASTEEL® COMPOSITE BARRIER SYSTEMS SPECIFICATION DETAILS

Stud Channel Sizes

Height of Size of steel channel (mm x mm x mm) for fire resistance
partition – m period (minutes)
60 mins 90 mins 120mins 180mins 240mins
0–6 80 x 60 x 3 80 x 60 x 3 80 x 60 x 3 80 x 60 x 3 80 x 60 x 3
6–9 80 x 60 x 3 80 x 60 x 3 150 x 60 x 3 150 x 60 x 3 150 x 60 x 3
9 – 12 150 x 60 x 3 150 x 60 x 3 150 x 60 x 3 150 x 60 x 3 150 x 60 x 3
12 – 15 150 x 60 x 3 175 x 60 x 3 175 x 60 x 3 175 x 60 x 3 2 no.
150 x 60 x 3
back to back

Insulated Partitions

Board configuration either side of steel channel
Fire resistance Thickness of Thickness of
®
– minutes PROMATECT -250 (mm) DURASTEEL® (mm)
E240, El60 12 6
CF418 – D
Doorsets E240, El90 12 9.5
CF424 – Partitions and Ceilings E240, El120 15 9.5
CF480 – Ductwork E240, El180 20 9.5
CF607 – Composite Barriers E240, El 240 25 9.5

16



240 MINUTE DURASTEEL® PROTECTED ZONE (E 240 - EI 15)

If a ﬁre breaks out near the area where a compartment wall meets a roof, there is a risk
that it will spread over the roof to the adjoining compartment. To reduce the risk, Approved
Document B requires protection to be installed to a protected zone of the roof 1500mm either
side of the compartment wall. However, for more onerous circumstances, the FPA Design
Guide suggests a minimum of 2500mm, or up to 5000mm dependent upon the orientation of
the ridge and the presence of a sprinkler system.

A DURASTEEL® protected zone detail is required for instances where a DURASTEEL®
ﬁre barrier (acting as a compartment wall) abuts a roof system. Please contact Promat UK
Technical Services department for further information.

17



DURASTEEL® FIRE BARRIER SPECIFICATIONS

DURASTEEL® Fire Barrier E 240 Integrity only (formerly STI 240)
Fire resistance: 240 minutes integrity only. (Fire attack from either face)
(formerly referred to as the STI 240 system)
Channel (minimum): 80mm x 60mm x 3mm (for heights up to 6m)
Overall width: 89.5mm
Weight (nominal): 27kg/m2
Estimated sound reduction: 33dB

Perimeter channels fastened to surrounding construction with M10 or M12
all-steel expanding anchors (or equivalent for alternative types of supporting
construction) at 500mm maximum centres.
Steel channel sizes for barrier heights up to 15 metres
The vertical channels are set at a maximum 1200mm centres. Horizontal and
vertical channel members either welded together or joined with steel angle cleats, Height of Channel size Estimated Sound
minimum 60mm x 60mm x 3mm thick x 60mm long, fastened to each channel
Barrier (m) (mm x mm x mm) Insulation Rw (dB)
member with two M10 steel bolts and nuts.
0–6 80 x 60 x 3 33
A single layer of 9.5mm DURASTEEL® fixed on one side of channel with M5.5 steel 6–9 150 x 60 x3 33
self drill and tap Tek screws at 250mm nominal centres. Fixings a minimum of Two 150 x 60 x 3
9 – 12 33
12mm from edge of sheet and a maximum of 50mm from corners. Length of fixing back to back
to be sufficient to ensure appropriate penetration of screw thread in accordance
Two 175 x 60 x 3
with screw manufacturer’s recommendations. 12 – 15 33
back to back
Vertical board joints coincide with studs, horizontal board joints are backed by
Back to back channels fastened together with M10 steel bolts and nuts at 500mm
steel channel the same size as the vertical studs. maximum centres. The vertical joints in the DURASTEEL® should be offset by 30mm

Expansion allowance will be required for barriers above 4 metres high. Please from the centreline of the back-to-back studs, to avoid a straight through path for hot
gases. Horizontal channels are single channels.
contact Promat UK Technical department for further information.

DURASTEEL® Fire Barrier E 240 – EI 60 (formerly STI 240/60)
Fire resistance: 240 minutes integrity - 60 minutes insulation.
(Fire attack from either face)
(formally referred to as the STI 240/60 System)
Overall width: 118mm
Weight (nominal): 51kg/m2 9.5mm DURASTEEL® fillet fixed on both sides of channel. Fillet strips to overlap channel by
Estimated sound reduction: 42dB minimum of 20mm on both sides.

Perimeter channels fastened to surrounding construction with M10 or M12 9.5mm DURASTEEL® sheets fixed through fillet on both sides of the channel with M5.5
all-steel expanding anchors (or equivalent for alternative types of supporting steel self drill and tap Tek screws at 250mm nominal centres. Fixings a minimum of
construction) at 500mm maximum centres. 12mm from edge of sheet and a maximum of 50mm from corners. Length of fixing to be

The vertical channels are set at a maximum 1200mm centres. Horizontal and sufficient to ensure appropriate penetration of screw thread in accordance with screw

vertical channel members either welded together or joined with steel angle cleats, manufacturer’s recommendations.

minimum 60mm x 60mm x 3mm thick x 60mm long, fastened to each channel Vertical board joints coincide with studs, horizontal board joints are backed by steel channel

member with two M10 steel bolts and nuts. the same size as the vertical studs. Expansion allowance will be required for barriers above
4 metres high. Please contact Promat UK Technical department for further information.


Height of Channel size Durateel fillets Rock wool Estimated Sound
Barrier (m) (mm x mm x mm) per face infill Insulation Rw (dB)
0–6 80 x 60 x 3 1 None 42
6–9 150 x 60 x3 1 None 42
9 – 12 Two 150 x 60 x 3 back to back 1 None 42
12 – 15 Two 200 x 60 x 3 back to back 1 None 42

Back to back channels fastened together with M10 steel bolts and nuts at 500mm maximum centres. The vertical joints in the DURASTEEL® should be offset by 30mm from
the centreline of the back-to-back studs, to avoid a straight through path for hot gases. Horizontal channels are single channels.

18



DURASTEEL® FIRE BARRIER SPECIFICATIONS

DURASTEEL® Fire Barrier E 240 – EI 120 (formerly STI 240/120)
(Fire attack from either face) (formally referred to as the STI 240/120 System)
by minimum of 20mm on both sides. 9.5mm DURASTEEL® sheets fixed through the fillet
on both sides of channel, with M5.5 steel self drill and tap Tek screws at 250mm nominal
Estimated sound reduction: 47dB
centres. Fixings a minimum of 12mm from edge of sheet and a maximum of 50mm from
Perimeter channels fastened to surrounding construction with M10 or M12 corners. The length of fixing to be sufficient to ensure appropriate penetration of screw
all-steel expanding anchors (or equivalent for alternative types of supporting thread, in accordance with manufacturer’s recommendations. Vertical board joints coincide
construction) at 500mm maximum centres. with studs, horizontal board joints are backed by steel channel the same size as the vertical
studs. Rock wool infill, according to the table below, is fitted into the channels. The layers
are staggered by a minimum of 150mm.
vertical channel members either welded together or joined with steel angle cleats,
minimum 60mm x 60mm x 3mm thick x 60mm long, fastened to each channel If the rock wool does not fill the cavity, it must be fastened into position with 2.5mm-
member with two M10 steel bolts and nuts. diameter steel stud-welded pins and 38mm-diameter spring steel washers. The pins are
positioned in a grid 400mm x 400mm maximum. Expansion allowance will be required for
9.5mm DURASTEEL® fillet strips fixed on both sides of channel, number of fillet
barriers above 4 metres high. Please contact Promat UK Technical department for
strips according to requirements in Table below. Fillet strips to overlap channel
further information.


0–6 80 x 60 x 3 1 2 x 40mm x 140kg/m3 47
6–9 150 x 60 x3 None 3 x 50mm x 80kg/m3 51
9 – 12 Two 150 x 60 x 3 back to back None 3 x 50mm x 80kg/m3 51
12 – 15 Two 200 x 60 x 3 back to back None 4 x 50mm x 60kg/m3 53

DURASTEEL® Fire Barrier EI 240 (formerly STI 240/240)
(Fire attack from either face) (formally referred to as the STI 240/240 System)
Channel (minimum): 80 x 60 x 3 (for heights up to 6m)
Weight (nominal): 72kg/m2 9.5mm DURASTEEL® sheets fixed through the fillet on both sides of channel, using M5.5 steel
Estimated sound reduction: 50dB self drill and tap Tek screws at 250mm nominal centres. Fixings a minimum of 12mm from edge
of sheet and a maximum of 50mm from corners. The length of fixing to be sufficient to ensure
Perimeter channels fastened to surrounding construction with M10 or M12
appropriate penetration of screw thread, in accordance with manufacturer’s recommendations.
all-steel expanding anchors (or equivalent for alternative types of supporting
construction) at 500mm maximum centres. Vertical board joints coincide with studs, horizontal board joints are backed by steel
channel the same size as the vertical studs.
vertical channel members either welded together or joined with steel angle cleats, Rock wool infill, according to the table below, is fitted into the channels. The layers are
minimum 60mm x 60mm x 3mm thick x 60mm long, fastened to each channel staggered by a minimum of 150mm. If the rock wool does not fill the cavity, it must be
member with two M10 steel bolts and nuts. fastened into position with 2.5mm-diameter steel stud-welded pins and 38mm-diameter
9.5mm DURASTEEL® fillets fixed on both sides of channel, number of fillet strips spring steel washers. The pins are positioned in a grid 400mm x 400mm maximum.
according to requirements in Table below. Fillet strips to overlap channel by
Expansion allowance will be required or barriers above 4 metres high. Please contact
minimum of 20mm on both sides.
Promat UK Technical department for further information.


0–6 80 x 60 x 3 2 3 x 40mm x 140kg/m3 50
3
6–9 150 x 60 x3 2 3 x 50mm x 100kg/m 55
9 – 12 Two 150 x 60 x 3 back to back 2 3 x 50mm x 100kg/m3 55
12 – 15 Two 200 x 60 x 3 back to back 1 4 x 50mm x 80kg/m3 56

19



DURASTEEL® CEILING SPECIFICATIONS

DURASTEEL® SUSPENDED CEILING MEMBRANE
(E 240 - Integrity Only) Fire from above or below
Fire resistance: 240 minutes integrity only. (Fire attack from above or below)
Channel (minimum): 80mm x 60mm x 3mm
Overall depth: 89.5mm

Perimeter channels of ceiling membrane fastened to surrounding construction
with M10 or M12 allsteel expanding anchors (or equivalent for alternative types of
supporting construction) at 500mm maximum centres.

Primary channels at 1200mm maximum centres, supported from building structure
above the ceiling membrane with steel drop rods at 1.5m centres. Threaded rods pass member with two M10 steel bolts and nuts.
through clearance holes in the upper flange of the channels and are fastened with steel
Where an expansion allowance is provided within the primary channels, steel jointing
hexagon full nuts.
channels, minimum 50mm flanges x 3mm thick, are fastened to the primary channels
Diameter of drop rods such that the tensile stress within the rods does not exceed with M10 steel bolts and nuts. The width of the jointing channel (web dimensions)
6N/mm2 for fire ratings up to 240 minutes. (This may be increased to 10N/mm2 if only should be such that it is a close fit within the primary channels.
a 120 minutes fire rating is required).
On one side of the expansion gap the primary and jointing channels are connected
9.5mm DURASTEEL® boards fastened to lower flange of steel channels with M5.5 with minimum two M10 bolts. On the opposite side the channels are connected,
steel self-drill and tap Tek screws at 200mm nominal centres. Fixings a minimum of through slotted holes, with minimum two M10 bolts fitted with fusible washers.
12mm from edge of sheet and a maximum of 50mm from corners. Length of fixing
For fire attack from below, an expansion allowance of at least 6mm per metre is
to be sufficient to ensure appropriate penetration of screw thread in accordance with
required for primary channels longer than 4m.
screw manufacturer’s recommendations.
For fire attack from above, an expansion allowance of at least 6mm per metre is
Longitudinal board joints coincide with primary channels, transverse board joints
required for all sizes of ceiling.
backed by steel channel the same size as the primary channels. Longitudinal and
transverse channel members are either welded together or joined with steel angle As drop rods support the ceiling, the length and width of ceiling membrane
cleats, minimum 60mm x 60mm x 3mm thick x 60mm long, fastened to each channel is unrestricted.

(E 240 – EI 120) Fire from below
Fire resistance: 240 minutes integrity – 120 minutes insulation.
(Fire attack from below)

Perimeter channels of ceiling membrane fastened to surrounding construction Longitudinal board joints coincide with primary channels, transverse board joints
with M10 or M12 all steel expanding anchors (or equivalent for alternative types of backed by steel channel the same size as the primary channels.
supporting construction) at 500mm maximum centres. Longitudinal and transverse channel members are either welded together or joined
Primary channels at 1200mm maximum centres, supported from building structure with steel angle cleats, minimum 60mm x 60mm x 3mm thick x 60mm long, fastened
above the ceiling membrane with steel drop rods at 1.5m centres. Threaded rods pass to each channel member with two M10 steel bolts and nuts.
through clearance holes in the upper flange of the channels and are fastened with steel Rock wool insulation 80mm x 140 kg/m3 nominal density, fitted over the soffit layer of
hexagon full nuts. DURASTEEL® by filling the channels. Joints in layers of rock wool overlap by at least 150mm.
Diameter of drop rods such that the tensile stress within the rods does not exceed Where an expansion allowance is provided within the primary channels, steel jointing
6N/mm2 for fire ratings up to 240 minutes. (This may be increased to 10N/mm2 if only channels, minimum 50mm flanges x 3mm thick, are fastened to the primary channels
a 120 minutes fire rating is required). with M10 steel bolts and nuts. The width of the jointing channel (web dimensions)
9.5mm DURASTEEL® fillet strips fitted over the upper and lower faces of the channel should be such that it is a close fit within the primary channels.
members. Fillets must overlap the channels by at least 20mm on both sides. On one side of the expansion gap the primary and jointing channels are connected
9.5mm DURASTEEL® boards fastened (through fillet strips) to lower flange of steel with minimum two M10 bolts. On the opposite side the channels are connected,
channels with M5.5 steel self-drill and tap Tek screws at 200mm nominal centres. through slotted holes, with minimum two M10 bolts fitted with fusible washers.
Fixings a minimum of 12mm from edge of sheet and a maximum of 50mm from For fire attack from below, an expansion allowance of at least 6mm per metre is
corners. Length of fixing to be sufficient to ensure appropriate penetration of screw required for primary channels longer than 4m.
thread in accordance with screw manufacturer’s recommendations.
As drop rods support the ceiling, the length and width of ceiling membrane is unrestricted.

20




(EI 120) Fire from above or below
Fire resistance: 120 minutes integrity and insulation (Fire from above or below)
Overall depth: 166mm

with M10 or M12 all steel expanding anchors (or equivalent for alternative types of
Rock wool insulation 80mm x 140 kg/m3 nominal density, laid over the steel channels.
Joints in layers of rock wool overlap by at least 150mm.
above the ceiling membrane with steel drop rods at 1.5m centres. Threaded rods pass
with M10 steel bolts and nuts. The width of the jointing channel (web dimensions)
hexagon full nuts.
should be such that it is a close fit within the primary channels.
Diameter of drop rods such that the tensile stress within the rods does not
exceed 10N/mm2.
with minimum two M10 bolts. On the opposite side the channels are connected,
6 mm DURASTEEL® boards fastened to lower flange of steel channels with M5.5 steel through slotted holes, with minimum two M10 bolts fitted with fusible washers.
self-drill and tap Tek screws at 200mm nominal centres. Fixings a minimum of 12mm
from edge of sheet and a maximum of 50mm from corners. Length of fixing to be
sufficient to ensure appropriate penetration of screw thread in accordance with screw
manufacturer’s recommendations. Longitudinal board joints coincide with primary For fire attack from above, an expansion allowance of at least 6mm per metre is
channels, transverse board joints backed by steel channel the same size as the required for all sizes of ceiling.
primary channels.
As drop rods support the ceiling, the length and width of ceiling membrane
Longitudinal and transverse channel members are either welded together or joined is unrestricted.
with steel angle cleats, minimum 60mm x 60mm x 3mm thick x 60mm long, fastened
to each channel member with two M10 steel bolts and nuts.

(E 240 – EI 120) Fire from above or below (Method 1)
Fire resistance: 240 minutes integrity – 120 minutes insulation (Fire from above or below)

Rock wool insulation 80mm x 140 kg/m3 nominal density, laid over the steel channels.
Joints in layers of rock wool overlap by at least 150mm.
hexagon full nuts. Where an expansion allowance is provided within the primary channels, steel jointing
Diameter of drop rods such that the tensile stress within the rods does not exceed
6N/mm2 for fire ratings up to 240 minutes. (This may be increased to 10N/mm2 if only
9.5 mm DURASTEEL® boards fastened to lower flange of steel channels with M5.5
steel self drill and tap Tek screws at 200mm nominal centres. Fixings a minimum of
through slotted holes, with minimum two M10 bolts fitted with fusible washers.
12mm from edge of sheet and a maximum of 50mm from corners. Length of fixing
to be sufficient to ensure appropriate penetration of screw thread in accordance with For fire attack from below, an expansion allowance of at least 6mm per metre is
screw manufacturer’s recommendations. required for primary channels longer than 4m.

Longitudinal board joints coincide with primary channels, transverse board joints For fire attack from above, an expansion allowance of at least 6mm per metre is
backed by steel channel the same size as the primary channels. required for all sizes of ceiling.

Longitudinal and transverse channel members are either welded together or joined As drop rods support the ceiling, the length and width of ceiling membrane
is unrestricted.

21




(E 240 – EI 120) Fire from above or below (Method 2)
Fire resistance: 240 minutes integrity – 120 minutes insulation
(Fire from above or below)
Channel (minimum): 60mm x 150mm x 60mm x 3mm
Overall depth: 169mm
Longitudinal and transverse channel members are either welded together or joined
with M10 or M12 allsteel expanding anchors (or equivalent for alternative types of
Rock wool insulation 80mm x 140 kg/m3 nominal density, fitted over the soffit layer of
DURASTEEL® by filling the steel channels. Joints in layers of rock wool overlap by at least
150mm.
hexagon full nuts. Where an expansion allowance is provided within the primary channels, steel jointing
6N/mm2 for fire ratings up to 240 minutes. (This may be increased to 10N/mm2 if only
9.5 mm DURASTEEL® boards fastened to upper and lower flange of steel channels
with M5.5 steel self drill and tap Tek screws at 200mm nominal centres. Fixings
through slotted holes, with minimum two M10 bolts fitted with fusible washers.
a minimum of 12mm from edge of sheet and a maximum of 50mm from corners.
Length of fixing to be sufficient to ensure appropriate penetration of screw thread in For fire attack from below, an expansion allowance of at least 6mm per metre is
accordance with screw manufacturer’s recommendations. required for primary channels longer than 4m. For fire attack from above, an expansion
allowance of at least 6mm per metre is required for all sizes of ceiling.
backed by steel channel the same size as the primary channels. As drop rods support the ceiling, the length and width of ceiling membrane
is unrestricted.

(EI 240) Fire from below
Fire resistance: 240 minutes integrity & insulation. (Fire attack from below)
Channel (minimum): 60mm x 150mm x 60mm x 3mm

Longitudinal and transverse channel members are either welded together or joined
Primary channels at 1200mm maximum centres, supported from building structure to each channel member with two M10 steel bolts and nuts.
Rock wool insulation 150mm x 140 kg/m3 nominal density, fitted over the soffit layer of
DURASTEEL® by filling the channels. Joints in layers of rock wool overlap by at least 150mm.
hexagon full nuts.
6N/mm2 for fire ratings up to 240 minutes.
9.5mm DURASTEEL® fillet strips fitted over the upper and lower faces of the channel should be such that it is a close fit within the primary channels.
members. Fillet must overlap the channels by at least 20mm on both sides.
9.5mm DURASTEEL® boards fastened (through fillet strips) to lower flange of steel with minimum two M10 bolts. On the opposite side the channels are connected,
channels with M5.5 steel self-drill and tap Tek screws at 200mm nominal centres. through slotted holes, with minimum two M10 bolts fitted with fusible washers.
Fixings a minimum of 12mm from edge of sheet and a maximum of 50mm from
corners. Length of fixing to be sufficient to ensure appropriate penetration of screw
thread in accordance with screw manufacturer’s recommendations.
As drop rods support the ceiling, the length and width of ceiling membrane
is unrestricted.
backed by steel channel the same size as the primary channels.

22


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