The purpose of this rule is to provide special inspectors with a standard inspection procedure for spray-applied fire-resistive material (SFRM) as required by Section 1701.5, Item 10 of the Seattle Building Code. This rule was developed to provide consistent and accurate inspection methods.

1.0 Responsibilities

1.1 Authorization

1.1.1. Inspections of SFRM shall be made only by a DPD inspector, or a WABO (Washington Association of Building Officials) or DPD-approved inspection/testing agency, unless otherwise approved by the building official.

1.1.2. Only special inspectors registered in the category of SFRM shall perform such inspections under the supervision of the approved testing/inspection agency.

1.2 Approved Plans

1.2.1 SFRM SHOP DRAWINGS MUST BE SUBMITTED TO

AND APPROVED BY DPD PRIOR TO APPLICATION OF SFRM AS REQUIRED BY DIRECTOR’S RULE 6-99.

All inspections shall be made in accordance with the DPD-approved shop drawings that clearly identify the classification (sprayed fiber, or cementitious mixtures) and density (regular, medium, or high density) of SFRM and the thickness of SFRM required for the primary, secondary, and other framing elements.

1.2.2 Members carrying wind and earthquake forces in combination with gravity loads are included in the definition of primary structure. Bracing used to reduce the effective length of a column shall have the same fire resistance rating as the column.

1.2.3 Structural frame members carrying only wind or earthquake forces are not required to have a fire resistance rating.

1.2.4 All reductions in thickness of the SFRM at beam web penetrations taken according to Section 5.8 below shall be noted on the DPD-approved shop drawings.

1.2.5 Inspected areas shall be marked on a reduced plan provided by

the owner and maintained on the jobsite.

1.3 Preconstruction Conference

The contractor shall hold a meeting with the SFRM subcontractor, DPD’s representative, and the special inspector for the purpose of determining the scope and methods of inspection and responsibility for "follow-up" inspections, including patching of damaged and weathered areas. The plans (shop drawings) must be submitted to DPD, approved, and available at the jobsite prior to this meeting.

2.0 Request for Inspection and Scheduling

The person doing the work shall initiate the request for inspection. It is the responsibility of the general contractor to ensure that special inspections are scheduled in a timely manner.

3.0 Frequency of Inspection

Inspections will be required after each floor or 10,000 square feet to which SFRM has been applied, whichever quantity is less. Inspections are required for each classification (sprayed fiber or cementitious mixtures) and density (regular, medium, and high density) of SFRM applied and for each type of substrate condition encountered (bare, primed, and painted steel). If substrate conditions change during erection, inspections will be required of the new conditions. NO SFRM SHALL BE COVERED PRIOR TO INSPECTION.

4.0 Reports

The approved inspection/testing agency shall promptly report the results of their inspections in writing to the owner or the owner’s representative and DPD. Inspections must be recorded on separate data sheets for each classification and density of SFRM and substrate condition combination, for example, regular density SFRM over bare steel, or medium density SFRM over primed steel, etc. One copy of these reports must be maintained on the jobsite. The report shall be submitted after completion of SFRM application on each floor or 10,000 square feet, whichever quantity is less, and at such time as the tested area is still available for ready correction of cited deficiencies.

5.0 Inspection Procedure for SFRM

5.1 Prior Inspections

Verify that all inspections of structural steel members and connections have been completed in the area to be sprayed before SFRM application is started.

5.2 Substrate Condition

The substrate condition shall be inspected in accordance with UBC Standard 7-6, Section 7.603.2. Substrate temperature must be at least 40° F at the time of SFRM application and for at least 24 hours after application. Substrate temperatures down to 35° F may be allowed at the time of application, and for a specified period after application, if the manufacturer’s published instructions permit it for the product applied and jobsite conditions. A copy of the manufacturer’s product application specifications shall be kept on the jobsite in a readily accessible location until all SFRM inspections and corrections have been completed.

5.3 Approved Materials

The SFRM shall be verified as conforming to the classification and density indicated on the DPD-approved SFRM shop drawings.

5.4 Preliminary Thickness Determination for all Structural Frame Members and Floor Sections

Visually check all structural frame members and floor sections in each area sprayed. All generalized areas appearing to be less than required thickness, damaged areas, and dropouts are to be checked for thickness and marked for recoating where required. The applicator will be directed to recoat all deficient areas.

5.5 Flutes and Valleys

Where open flutes or valleys of steel deck sections occur over beams, they shall be filled solid.

 

 

5.6 Special Considerations for Exposed SFRM Below 8 Feet in Parking Garages When High-Density SFRM is Specified

When specified, exposed SFRM in parking garages on those portions of beams, columns, ceilings, or other structural members less than 8 feet from a floor and in areas subject to vehicular traffic, must meet the following minimum performance values:

a. a minimum bond strength of 7,000 pounds per square foot (psf) when tested in accordance with ASTM E 736;

b. a minimum compressive strength of 50,000 psf when tested in accordance with ASTM E 761; and

1. a minimum density of 35 pcf when tested in accordance with ASTM E 605.

When applying such SFRM, manufacturer’s recommended installation procedures shall be followed.

This section does not apply to unexposed SFRM, such as that protected by a furred wallboard assembly, cement, cement plaster and lath, or a similar protective construction approved by the building official.

5.7 Pipe, Conduit, and Similar Installations

Ducts, conduit, piping, and similar mechanical, electrical, and plumbing installations shall not be embedded within the required thickness of the SFRM.

5.8 SFRM Thickness Reduction at Steel Beam Web Penetrations

SFRM thickness reduction at steel beam web penetrations, when noted on the shop drawings, must have increased SFRM thickness on surfaces adjacent to the penetration extending 12 inches in all directions from the edge of the web penetration. This section only applies to those SFRM products that have an approved assembly rating that describes methods for SFRM thickness reductions at flange tips (for example, 1998 UL Fire Resistance Directory Design Number N782 and N805, as amended).

5.9 Test Method for Thickness

The test method for thickness of the SFRM shall be conducted in accordance with UBC Standard 7-6, Section 7.603.

The random areas selected for test measurements shall be marked on a reduced floor plan before inspection is started. Results of test measurements are to be recorded on data sheets. Test locations on columns and beams are to be selected at the end thirds or middle thirds, in a rotating order to vary the location of test areas.

It is preferable to conduct thickness tests before medium and high-density SFRMs have cured and are too hard to test for thickness using standard procedures. The applicator must adjust the thickness of the freshly applied SFRM to yield thickness after cure, in accordance with the SFRM manufacturer’s recommendations. If the tests are conducted after curing, any holes made to accommodate the thickness-gauge pin must be closed off immediately following the test using the same SFRM.

Where thickness is less than that required, the condition shall be corrected. The location of any uncorrected areas shall be reported to the building official.

5.10 Test Methods for Density

The test to determine density of SFRM shall be conducted in accordance with UBC Standard 7-6, Section 7.604.

Density determinations may be made in accordance with either Section 7.604.3, or the alternative density displacement method set forth in Section 7.604.4. DPD equally accepts the results of either method.

No sample shall have a density less than 5 percent below the specified density. Where the density is less than 5 percent below the specified density, the work shall be corrected to the satisfaction of the building official.

5.11 Test Method for Cohesion/Adhesion (Bond-Strength)

The test to determine the cohesion/adhesion of SFRM shall be conducted in accordance with UBC Standard 7-6, Section 7.605.

At the beginning of SFRM application, at least one cohesion/adhesion test shall be taken from a column, beam, and deck at a location representative of the general condition of the substrate. Additional cohesion/adhesion tests shall be taken whenever the substrate condition changes, freezing conditions occur within 24 hours after SFRM application, or the suitability of the substrate is questionable for any other reason. The tests shall be conducted only after the in-place SFRM has cured and shall be taken at the location(s) under question.

At least one cohesion/adhesion test shall be taken from a column, beam, and deck for exposed SFRM applied as set forth in Section 5.6 above.

No sample shall have a cohesive/adhesive force of less than 150 psf. Where the cohesive/adhesive force is less than 150 psf, the work shall be corrected to the satisfaction of the building official.

5.12 Patching Inspections

All patching of damaged areas on beams, columns and bracing at the exterior of the building will be approved by the inspection agency no more than 24 hours prior to erection of exterior cladding. All patching of damaged areas on beams, columns, bracing, and floor sections at the interior of the building must be approved by the building official before any wall or ceiling cover is allowed.

5.13 Final Acceptance Inspection

Final inspection will be made when all corrections are completed. Final inspection of exterior surface shall not be performed until cladding is completed. SFRM shall not show upon complete drying or curing any deep or wide cracks, voids, spalls or any exposure of the substrate. The inspection agency will submit a final acceptance report and test data sheets to the general contractor and the building official on completion of each floor.