Kingsa 60mts Body Cote - Unlocked

Title:
Fire Resistance test of two single

leaf doorsets in general
accordance with
BS 476: Parts 20 & 22: 1987
Section 6
BWA Report No:
2250900a
Test Applicant:
Danube Group
Jebel Ali
UNITED ARAB EMIRATES
Test Date:
14th March 2008
© Bodycote Warringtonfire (Aus) Pty Ltd 2008

Bodycote Warringtonfire (Aus) Pty Ltd (formerly known as Warrington Fire Research (Aust) Pty Ltd)
NATA Accredited Laboratory in the field of Heat and Temperature since 1991.
Laboratory - Unit 2, 409 - 411 Hammond Road, Dandenong, Victoria 3175, Australia.
NSW Office – Level 20, Suite 2002A, 44 Market Street, Sydney, NSW, 2000
BWA Report No 2250900
Issue Number 2250900a.1
Page 2 of 39
DOCUMENT REVISION STATUS
Date Issued Issue No Description
2nd April 2008 2250900a.1 Initial issue
SIGNATORIES
Prepared by: Reviewed by:
A. F. Rayner K. G. Nicholls
On behalf of Bodycote Warringtonfire (Aus) Pty Ltd
GENERAL CONDITIONS OF USE

This report may only be reproduced in full without modifications by the
report applicant only. Copies, extracts or abridgments of this report in any
form shall not be made distributed or published by other organisations
or individuals without the permission of Bodycote Warringtonfire (Aus) Pty Ltd.

Page 3 of 39
CONTENTS
1 CONSTRUCTION DETAILS 4
Test Assembly 4
Test Specimen 4
Assembly and Installation Methods 4
Orientation 4
2 SCHEDULE OF COMPONENTS 5
3 TEST PROCEDURE 8
Statement of compliance 8
Variations from test standards 8
Pre-test conditioning 8
Sampling / Specimen Selection 8
Ambient Temperature 8
Test Duration 8
Instrumentation and Equipment 9
4 TEST MEASUREMENTS 9
Furnace Temperature and Pressure Measurements 9
Specimen Temperatures 9
Deflection Measurements 9
Heat flux Measurement 9
Observations 10
5 TEST RESULTS 11
6 APPLICATION OF TEST RESULTS 12
Test Limitations 12
Variations from the Tested Specimens 12
Uncertainty of measurement 12
APPENDIX 1 DRAWINGS OF TEST ASSEMBLY 13
APPENDIX 2 TEST OBSERVATIONS 21
APPENDIX 3 INSTRUMENTATION POSITIONS 23
APPENDIX 4 TEST DATA 27
A 4.1 Furnace Temperature 27
A 4.2 Furnace Pressure 27
A 4.3 Specimen Temperatures 28
A 4.4 Deflection Measurements 34
A 4.5 Heat Flux Measurement 35
APPENDIX 5 PHOTOGRAPHS 36

Page 4 of 39
1 CONSTRUCTION DETAILS
TEST ASSEMBLY
The test assembly comprised a nominal 3200 mm x 3200 mm x 140 mm thick
hollow core concrete block wall incorporating two single leaf particleboard core
doorsets.
TEST SPECIMEN
The test specimens comprised two single leaf particle board core doorsets
referred to as Door A and Door B for the purposes of this test report. Further
details are provided in Figures A1.1 to A1.8 and the schedule of components
Section 2. The majority of dimensions have been provided by the test applicant
and have been verified wherever practical by Bodycote Warringtonfire (Aus) Pty
Ltd.
ASSEMBLY AND INSTALLATION METHODS

The hollow core concrete block wall was built into a steel restraint frame,
incorporating openings for the doorsets, by a building contractor at BWA
Melbourne commencing on the 19th February 2008 and under the supervision of
a BWA representative. The test applicant supplied and installed (installed by a
contractor nominated by the test applicant) the single leaf doorsets (including
leafs, frames and all door hardware) commencing on the 12th March 2008 and
under the supervision of a BWA representative.
ORIENTATION
The specimen was installed with Door A swinging towards the furnace and
Door B swinging away from the furnace.

Page 5 of 39
2 SCHEDULE OF COMPONENTS
ITEM DESCRIPTION
DOOR A
Leaf Size 2040 mm high x 825 mm wide x 50 mm (nominal) thick door leaf.
Leaf Core The leaf core was stated by the test applicant to be nominally 50 mm
thick (made of two 25 mm thick sheets laminated together) and
designated as DANUBE “KINGSA” Core supplied by DANUBE.
KINGSA, as stated by the test applicant, is a particleboard material and
has a nominal density of 695 kg/m3 at a nominal moisture content of
7+3%.
Leaf edging 8 mm thick (nominal) Meranti light hardwood with a nominal density, as
stated by the test applicant, of minimum 550 kg/m3.
Reinforcement Nil.
plates
Leaf Facing Nil.
Leaf Seals Lorient LP2004 (Type 617 - 20 mm x 4 mm) Intumescent Strip, as stated
by the test applicant, was rebated within the bottom of the door leaf.
Hinges Royde & Tucker 105 Hi-load hinges (lift-off) with 3-off screw fixings (nom
5 mm diameter x 60 mm long stainless steel screws) through each plate
to the door leaf and door frame. The hinges were fitted to the right hand
side of the door leaf (looking from the unexposed side) with the door
swinging towards the furnace. Hinge areas were additionally protected
with Lorient Intumescent Hinge Protection Kit, refer Figure A1.8.
Hinge Locations There were 3 hinges positioned at 210 mm, 1035 mm and 1855 mm
respectively from the sill to the centre of the hinge.
Frame The solid timber door frame was 90 mm wide x 55 mm thick with a door
seat rebate of nominally 20 mm deep x 53 mm wide. The frame was
made from Meranti hardwood of a nominal density, as stated by the test
applicant, of minimum 550 kg/m3. The frames were joined with a mitred
and tennon joint that was glued and screwed into position.
Frame Seals Lorient LP1504 (Type 617 – 15 mm x 4 mm Intumescent Fire Seal
interrupted by hinges) and LP1504DS (Type 617 – 15 mm x 4 mm
Intumescent Fire and Smoke Seal bypassing hinges), as stated by the
test applicant, were rebated within the perimeter of the frame.
Fixings The timber frame was secured to the opening in the masonry wall with
9-off (4-off per vertical side and 1-off in the head) No 12 x 100 mm long
socket head screws into plastic plugs, as stated by the test applicant, at
maximum spacing 600 mm and the top fixing nominally 150 mm from the
head.

Page 6 of 39
ITEM DESCRIPTION
Lockset Dorma 515 Fa Mortice lock (cylinder mortice lock) with striker centrally
located nominally 945 mm from the sill and a backset of nominally
60 mm. The lever handles (LANE Contractor series) were to the
unexposed and exposed sides. The latch throw was nominally 12 mm.
Mortice lockset was additionally protected with Lorient Intumescent Lock
Protection Kit, refer Figure A1.8.
Closer DORMA TS73V-EN2-4 fitted to exposed side of the doorset.
DOOR B
Leaf Size 2040 mm high x 825 mm wide x 50 mm (nominal) thick door leaf.
Leaf Core The leaf core was stated by the test applicant to be nominally 50 mm
thick (made of two 25 mm thick sheets laminated together) and
designated as DANUBE “KINGSA” Core supplied by DANUBE.
KINGSA, as stated by the test applicant, is a particleboard material and
has a nominal density of 695 kg/m3 at a nominal moisture content of
7+3%.
Leaf edging 8 mm thick (nominal) Meranti light hardwood with a nominal density, as
stated by the test applicant, of minimum 550 kg/m3.
Reinforcement Nil.
plates
Leaf Facing Nil.
Leaf Seals Lorient LP2004 (Type 617 - 20 mm x 4 mm) Intumescent Strip, as stated
by the test applicant, was rebated within the bottom of the door leaf.
Hinges Royde & Tucker 105 Hi-load hinges (lift-off) with 3-off screw fixings (nom
5 mm diameter x 60 mm long stainless steel screws) through each plate
to the door leaf and door frame. The hinges were fitted to the right hand
side of the door leaf (looking from the unexposed side) with the door
swinging away from the furnace. Hinge areas were additionally protected
with Lorient Intumescent Hinge Protection Kit, refer Figure A1.8.
Hinge Locations There were 3 hinges positioned at 210 mm, 1035 mm and 1855 mm
respectively from the sill to the centre of the hinge.
Frame The solid timber door frame was 90 mm wide x 55 mm thick with a door
seat rebate of nominally 20 mm deep x 53 mm wide. The frame was
made from Meranti hardwood of a nominal density, as stated by the test
applicant, of minimum 550 kg/m3. The frames were joined with a mitred
and tennon joint that was glued and screwed into position.
Frame Seals Lorient LP1504 (Type 617 – 15 mm x 4 mm Intumescent Fire Seal
interrupted by hinges) and LP1504DS (Type 617 – 15 mm x 4 mm
Intumescent Fire and Smoke Seal bypassing hinges), as stated by the
test applicant, were rebated within the perimeter of the frame.

Page 7 of 39
ITEM DESCRIPTION
Fixings The timber frame was secured to the opening in the masonry wall with
9-off (4-off per vertical side and 1-off in the head) No 12 x 100 mm long
socket head screws into plastic plugs, as stated by the test applicant, at
maximum spacing 600 mm and the top fixing nominally 150 mm from the
head.
Lockset Dorma 515 Fa Mortice lock (cylinder mortice lock) with striker centrally
located nominally 945 mm from the sill and a backset of nominally
60 mm. The lever handles (LANE Contractor series) were to the
unexposed and exposed sides. The latch throw was nominally 12 mm.
Mortice lockset was additionally protected with Lorient Intumescent Lock
Protection Kit, refer Figure A1.8.
Closer DORMA TS73V-EN2-4 fitted to exposed side of the doorset.
Supporting Construction
Description 140 mm thick hollow core concrete block wall.
Door Sill Four courses of solid concrete blocks 390 mm x 190 mm x 90 mm with
the top course laid perpendicular (except two half end blocks) to the wall
to form a sill for the doorsets. A screed of premixed mortar was applied
over the concrete blocks to a thickness of approximately 5mm to reduce
the door threshold clearance from the base of the door leaf to the sill.
Blocks above sill Eleven courses of hollow core concrete blocks were laid on the sill to
form the openings and an additional four courses were laid above the
openings including one lintel beam course which included a single D16
reinforcement rod with premixed concrete filling the void.
Sealant Lorient intumescent mastic was used to seal the gap (backed by
Rockwool) between the edge of the door frames and the openings in the
concrete block wall on both sides.

Page 8 of 39
3 TEST PROCEDURE
STATEMENT OF COMPLIANCE
The test was performed in general accordance with the requirements of
BS 476: Part 20: 1987 and BS 476: Part 22: 1987 Section 6 as appropriate for
insulated doorsets, other than the variations stated below.
VARIATIONS FROM TEST STANDARDS

The furnace temperature was measured by 6-off mineral insulated metal
sheathed Type K thermocouples with wire diameters not greater than 1 mm and
overall diameter of 3 mm with the measuring junction insulated from the sheath.
The thermocouples protruded a minimum of 25 mm from steel supporting tubes.
BS 476: Part 20: 1987 specifies the furnace temperature to be measured by 6-off
Nickel chromium/nickel aluminium wire contained within a mineral insulation and
in a heat resisting steel sheet of diameter 1.5 mm, the hot junctions being
electrically insulated from the sheath. The thermocouple hot junction shall
project 25 mm from a porcelain insulator.
This variation, is considered to make the test slightly more onerous, however
would not have significantly affected the results of the fire-resistance test.
The furnace pressure varied more than as prescribed by BS 476: Part 22: 1987
during the period of 30-35 minutes test duration but was below that prescribed
(maximum pressure level variation +2 Pa). The deviation was only minor
(pressure average was -3 Pa) and for a short period, therefore it is considered
that this variation would not have significantly affected the results of the
fire-resistance test.
PRE-TEST CONDITIONING
The specimen was stored in the test laboratory and was subjected to indoor
ambient normal laboratory conditions for 48 hours prior to testing.
SAMPLING / SPECIMEN SELECTION

The laboratory was not involved in the selection of the test specimen for test.
AMBIENT TEMPERATURE
The ambient temperature at the start of the test was 29°C and gradually
increased to a maximum of 30°C at the end of the test.
TEST DURATION
The test was terminated after approximately 79 minutes after agreement between
the test laboratory and applicant.

Page 9 of 39
INSTRUMENTATION AND EQUIPMENT

The instrumentation was provided in accordance with BS 476: Part 22: 1987
except for the furnace control thermocouples as mentioned above.
The furnace temperature was measured by 6-off mineral insulated metal
sheathed Type K thermocouples with wire diameters not greater than 1 mm and
overall diameter of 3 mm with the measuring junction insulated from the sheath.
The thermocouples protruded a minimum of 25 mm from steel supporting tubes.
The non fire side specimen temperatures were measured by Type K
thermocouples with wire diameters less than 0.5 mm diameter soldered to 12 mm
diameter × 0.2 mm thick copper discs covered by a 30 mm × 30 mm × 2.0 mm
inorganic insulating pads. The thermocouples positions are described in Table
A3.1, and are shown on Figure A3.1 in Appendix 3. A roving thermocouple was
available to measure temperatures at positions that appear hotter than the
positions monitored by fixed thermocouples.
Deflection measurements were taken from calibrated tapes, fixed to the test
specimen, using a Telescope Levelling Instrument (Dumpy Level) Model 200B, at
the positions shown on Figure A3.2 in Appendix 3.
The furnace pressure was measured approximately 1000 mm above sill level.
Cotton pads and gap gauges were available during the test to assess the
performance under the criteria for integrity up to unexposed face temperatures of
300°C for both Doorsets. After that time gap gauges only were available to
assess the performance under the criteria for integrity.
4 TEST MEASUREMENTS
FURNACE TEMPERATURE AND PRESSURE MEASUREMENTS

Furnace temperature and pressure data are provided in A4.1 and A4.2 in
Appendix 4.
SPECIMEN TEMPERATURES
Specimen temperature data is provided in A4.3 and Table A4.1 and A4.2 in
Appendix 4.
DEFLECTION MEASUREMENTS
Deflection measurement data is provided in A4.4 in Appendix 4.
HEAT FLUX MEASUREMENT

Heat Flux measurements are provided in A4.5 in Appendix 4.

Page 10 of 39
OBSERVATIONS
A table that includes observations of the significant behaviour of the specimen
and details of the occurrence of the various performance criteria specified in
BS 476: Part 22: 1987 is provided in Appendix 2. Photographs of the specimen
are included in Appendix 5.

Page 11 of 39
5 TEST RESULTS
The specimen achieved the following performance when tested in general
accordance with BS 476: Part 22: 1987 Section 6 as appropriate.
DOOR A
Loadbearing Capacity Not applicable
65 minutes
Integrity Failure by sustained flaming by virtue of flames
on unexposed side at bottom hinge corner of
door.
65 minutes
Insulation Insulation failure deemed to occur at time of
integrity failure.
DOOR B
Loadbearing Capacity Not applicable

Integrity No failure at 79 minutes
Insulation No failure at 79 minutes

Page 12 of 39
6 APPLICATION OF TEST RESULTS
TEST LIMITATIONS
The results of this fire test may be used to directly assess fire hazard, but it
should be recognized that a single test method will not provide a full assessment
of fire hazard under all fire conditions. The results only relate to the behaviour of
the specimen of the element of the construction under the particular conditions of
the test; they are not intended to be the sole criteria for assessing the potential
fire performance of the element in use nor do they necessarily reflect the actual
behaviour in fires.
VARIATIONS FROM THE TESTED SPECIMENS

This report details the methods of construction, the test conditions and the results
obtained when the specific element of construction described herein was tested
following the procedure outlined in BS 476: Parts 20 & 22: 1987. Any significant
variation with respect to size, constructional details, loads, stresses, edge or end
conditions, other than those allowed under the field of direct application in the
relevant test method, is not addressed by this report. It is recommended that any
proposed variation to the tested configuration should be referred to the test
applicant in the first instance to obtain appropriate documentary evidence of
compliance from Bodycote Warringtonfire (Aus) Pty Ltd or another Registered
Testing Authority.
UNCERTAINTY OF MEASUREMENT
Because of the nature of fire resistance testing and the consequent difficulty in
quantifying the uncertainty of measurement of fire resistance, it is not possible to
provide a stated degree of accuracy of the result.

Page 13 of 39
APPENDIX 1 DRAWINGS OF TEST ASSEMBLY
West East
hollow concrete blocks
Lintel with 1-off D16 rod

(7-off blocks)
DOOR A DOOR B
Every third course

tied to steel frame at
3210
mortar joint with

brick ties
2085
11 courses of
390x190x140 hollow
concrete blocks
14-off blocks turned

around 90° to form sill
end 1/2 blocks not
turned but flush with
exposed side
400
Four courses of
390x190x190 Solid
concrete blocks
518 900
1808 900
3227
UNEXPOSED FACE ELEVATION

OPENINGS FOR DOORSETS WITHIN MASONRY WALL
Figure A1.1: Masonry Wall Elevation

Page 14 of 39
Lorient Intumescent Mastic over

Rockwool between frame and
opening on both sides of each
doorset
= =
West East
132
DOOR A DOOR B
Nominal 600 MAX Centres
Swing In
UNEXPOSED FACE ELEVATION

DOORSET INSTALLATION
Figure A1.2: Test Specimen Elevation

Page 15 of 39
Door Frame 901mm Overall
Door Leaf width 826mm Overall

A
D D
Door Frame height 2085mm overall
B B
Door Leaf Height 2040mm Overall

Lockset strike positioned 950mm above floor level
C C
PROPOSED DANUBE
LORIENT MIDDLE EAST BUILDING
M ATERIALS TRADING LCC
KINGSA 60 DOOR
AL Q USAIS INDUSTRIAL AREA
DUBAI U.A.E
Specialising in Fire, Sm oke, Acoustic

and W eather Containment Systems
Tel + 971 4267 4339
Fax + 971 4267 5339 This drawing remains the property of Lorient Middle East Building Materials Trading LCC
Figure A1.3: Doorset Constructional Drawing (Provided By Client)

Page 16 of 39
SECTION AA
SECTION EE
DANUBE KINGSA 60 VERTICAL

L O R IE N T M ID D L E E A S T B U IL D IN G
M A T E R IA L S T R A D IN G L C C DOOR SECTIONS AA & EE
A L Q U S A IS IN D U S T R IA L A R E A
D U B A I U .A .E
S p e c ia lisin g in F ire , S m o ke , A co u s tic

a n d W e a th e r C o n ta in m e n t S yste m s
T e l + 97 1 42 67 43 39
F ax + 9 7 1 4 26 7 5 33 9
This drawing remains the property of Lorient Middle East Building Materials Trading LCC
Figure A1.4: Doorset Frame & Leaf Vertical Sectional Drawing (Provided By Client)

Page 17 of 39
DANUBE KINGSA 60 HORIZONTAL

DOOR SECTIONS BB & CC
SECTION BB
SECTION CC
Figure A1.5: Doorset Frame & Leaf Horizontal Sectional Drawing (Provided By Client)

R & T H105
Lift off hinge
20.5
2mm thick
intumescent pads
SECTION DD
32
Hinge type :
Page

Royde & Tucker H105 High Load
Butt Hinge bedded on
2mm thick intumescent pads
Issue Number
Figure A1.6: Doorset Hinge Details (Provided By Client)

BWA Report No
DANUBE KINGSA 60 HINGE

LOACTION AND INTUMESCENT
STRIP INTERRUPTIONS
This drawing remains the property of Lorient Middle East Building Materials Trading LCC
18 of 39
2250900a.1
2250900
LP1504DS
LP1504
INTUMESCENT STRIP
INTUMESCENT STRIP LOCATION IN DOOR
LOCATION IN DOOR BOTTOM
FRAME
Page

Intumescent Strip Type:
Door Frame - Lorient LP1504 and LP1504DS (Type 617)
Door Bottom - Lorient LP2004 (Type 617)
Issue Number
BWA Report No
DANUBE KINGSA 60 INTUMESCENT

STRIP LOCATIONS
Figure A1.7: Doorset Intumescent Strip locations (Provided By Client)

19 of 39
2250900a.1
2250900
Page 20 of 39
Figure A1.8: Lorient Intumescent Kit (Provided By Client)

Page 21 of 39
APPENDIX 2 TEST OBSERVATIONS

Time
Observation
Min Sec
DOORSET A
0 00 Fire-Resistance Test was commenced and ambient air temperature was
approximately 29°C.
2 16 Smoke emission was evident from the top half (vertical edges) of the doorset.
3 24 There was a reduction in the amount of smoke emission.
5 48 There was a further reduction in the amount of smoke emission.
6 39 There was an unidentified liquid emitted from the latchset.
12 00 Very minor smoke emission from doorset.
19 00 Minor flaming was evident under doorset on fire exposed side with molten
aluminium seeping under sill of doorset from fire exposed side.
20 36 Flaming under doorset on fire exposed side had ceased.
26 56 The unidentified liquid emitted from the latchset had evaporated.
38 58 Gap between bottom of door leaf and sill had diminished with the expansion of
the intumescent seal.
41 36 Small amount of smoke emission was evident from the top corners of the
doorset.
46 54 Top hinge side of door had begun to darken.
57 40 Applied cotton pad to top hinge side corner of doorset for a period of 15
seconds. No discolouration or glowing of cotton pad was evident.
60 23 Doorset has dropped and resting on sill.
65 25 Sustained flaming of unexposed face at sill level and base of doorset (for
longer than 10 seconds) near hinge edge. Integrity failure of Doorset A in
accordance with BS 476: Part 22: 1987.
69 15 Applied cotton pad to top hinge side corner of doorset for a period of 15
seconds. Minor discolouration of cotton pad was evident (no glowing).
69 59 Sustained flaming involving head of door was extinguished.
79 30 Fire resistance test was stopped at the request of the test applicant.
DOORSET B
0 00 Fire-Resistance Test was commenced and ambient air temperature was
approximately 29°C.
2 16 Smoke emission was evident from the top half (vertical edges) of the doorset.
3 24 There was a reduction in the amount of smoke emission.
3 45 There was a slight increase in the amount of smoke emission from the upper
hinge edge of the doorset.
5 48 There was a reduction in the amount of smoke emission and it had reduced to
a minimum.

Page 22 of 39
Time
Observation
Min Sec
6 39 There was an unidentified liquid emitted from the latchset.
12 00 Very minor smoke emission from doorset.
26 56 The unidentified liquid emitted from the latchset had evaporated.
29 16 Intumescent on underside of leaf had begun to activate.
35 16 Gap between bottom of door leaf and sill had diminished with the expansion of
the intumescent seal.
43 53 Slight amount of smoke emission was evident from latchset.
48 24 There was a slight increase in the amount of smoke emission from the latchset.
52 06 There was a slight amount of smoke emission from the underside of the door
leaf.
61 40 Some smoke emission was evident from the top hinge side corner of the
doorset.
68 40 Intermittent flaming was evident from under the doorset.
79 30 Fire resistance test was stopped at the request of the test applicant.

Page 23 of 39
APPENDIX 3 INSTRUMENTATION POSITIONS
D10
D11 C10
D9 C9 C11
C1
C2
D1
D2
C12
D6 D3 C8
D8 D12 C6
C3
D7
C7
C4 C5
D4 D5
x x
DOOR A DOOR B
y y
Figure A3.1: Thermocouple Locations
Table A3.1: Thermocouple Locations

Door A Door B
Location Location
T/C Description T/C Description
x y x y
D1 245 1535 Top west. C1 245 1535 Top west.
D2 655 1535 Top east. C2 655 1535 Top east.
D3 450 1025 Midpoint. C3 450 1025 Midpoint.
Leaf
Leaf
D4 245 515 Bottom west. C4 245 515 Bottom west.

D5 655 515 Bottom east. C5 655 515 Bottom east.
D6 90 1025 50 mm above latch. C6 93 1035 50 mm above latch.
D7 170 945 50 mm west of latch. C7 173 955 50 mm west of latch.
D8 27 450 West at mid-height. C8 18 450 West at mid-height.
D9 105 2067 Upper west corner. C9 85 2067 Upper west corner.
Frame
Frame
D10 450 2067 Mid-width of door C10 450 2067 Mid-width of door
leaf. leaf.
D11 795 2067 Upper east corner. C11 815 2067 Upper east corner.
D12 873 450 East at mid-height. C12 882 450 East at mid-height.

Page 24 of 39
DAF1
DA1
DBF1 DB1
DBC
DAC
DOOR A DOOR B
x x
DAF2 DBF2
DA2 DB2
y y
Figure A3.2: Deflection measurement Locations
Table A3.2: Deflection Locations

Door A Door B
Location Location
T/C Description T/C Description
X y x y
DA1 105 1980 Upper west corner of DB1 88 1700 Upper west corner of
leaf. leaf.
DAF1 27 1980 Upper west corner of DBF1 18 1670 Upper west corner of
frame. frame.
DAC 450 1075 Midpoint. DBC 450 1075 Midpoint.
DA2 105 50 Lower west corner of DB2 88 50 Lower west corner of
leaf. leaf.
DAF2 27 50 Lower west corner of DBF2 18 50 Lower west corner of
frame. frame.

Page 25 of 39
DOOR A EXPOSED FACE ELEVATION
Figure A3.3: Doorset A clearance measurements

Page 26 of 39
DOOR B UNEXPOSED FACE ELEVATION
Figure A3.4: Doorset B clearance measurements

Page 27 of 39
APPENDIX 4 TEST DATA
A 4.1 FURNACE TEMPERATURE
1200
1000
Temperature (°C)
800
600
400
200
0
0 15 30 45 60 75 90
Time (Minutes)
BS 476: Part 20: 1987 Mean Furn Max Furn Min Furn
Figure A4.1: Furnace Temperatures vs. Time.
A 4.2 FURNACE PRESSURE
Time Pressure Time Pressure

(Pa) (Pa)
(minutes) (minutes)
Avg Avg
5-10 1 45-50 0
10-15 0 50-55 1
15-20 0 55-60 0
20-25 -1 60-65 -1
25-30 0 65-70 0
30-35 -3 70-75 0
35-40 0 75-80 -2
40-45 1

Page 28 of 39
A 4.3 SPECIMEN TEMPERATURES
200
180
160
Temperature (°C)
140
120
100
80
60
40
20
0
0 15 30 45 60 75 90
Time (Minutes)
D1 D2 D3 D4 D5 Integrity Limit
Figure A4.2: Doorset A Quarter point Temperatures vs. Time
200
180
160
Temperature (°C)
140
120
100
80
60
40
20
0
0 15 30 45 60 75 90
Time (Minutes)
Average Integrity Limit
Figure A4.3: Average of Doorset A Quarter point Temperatures vs. Time

Page 29 of 39
200
180
160
Temperature (°C)
140
120
100
80
60
40
20
0
0 15 30 45 60 75 90
Time (Minutes)
D6 D7 Integrity Limit
Figure A4.4: Doorset A Miscellaneous Temperatures vs. Time
200
180
160
Temperature (°C)
140
120
100
80
60
40
20
0
0 15 30 45 60 75 90
Time (Minutes)
D8 D9 D10 D11 D12 Integrity Limit
Figure A4.5: Doorset A Frame Temperatures vs. Time

Page 30 of 39
200
180
160
Temperature (°C)
140
120
100
80
60
40
20
0
0 15 30 45 60 75 90
Time (Minutes)
C1 C2 C3 C4 C5
Figure A4.6: Doorset B Quarter point Temperatures vs. Time
200
180
160
Temperature (°C)
140
120
100
80
60
40
20
0
0 15 30 45 60 75 90
Time (Minutes)
Figure A4.7: Average of Doorset B Quarter point Temperatures vs. Time

Page 31 of 39
200
180
160
Temperature (°C)
140
120
100
80
60
40
20
0
0 15 30 45 60 75 90
Time (Minutes)
C6 C7
Figure A4.8: Doorset B Miscellaneous Temperatures vs. Time
200
180
160
Temperature (°C)
140
120
100
80
60
40
20
0
0 15 30 45 60 75 90
Time (Minutes)
C8 C9 C10 C11 C12
Figure A4.9: Doorset B Frame Temperatures vs. Time

Page 32 of 39
Table A4.1: Individual Test Specimen Temperatures limits for Doorsets

Temp (°C) at t (minutes) Limit1
Location T/C Description2
t=0 t=30 t=60 t=75 t=79 (Mins)
Doorset A
D1 Top west. 30 40 85 - - -
¼& D2 Top east. 30 40 81 - - -
mid- D3 Midpoint. 29 40 85 - - -
points D4 Bottom west. 29 39 88 - - -
D5 Bottom east. 29 39 87 - - -
D6 50 mm above latch. 29 58 85 - - -
Misc. D7 Top west corner. 29 43 88 - - -
D8 West at mid-height. 29 33 45 - - -
D9 Upper west corner. 29 32 50 - - -
D10 Mid-width of door leaf. 29 33 50 - - -
Timber D11 Upper east corner. 29 36 82 - - -
frame D12 East at mid-height. 29 36 51 - - -
Doorset B
C1 Top west. 29 40 84 95 119 -
¼& C2 Top east. 29 40 85 95 120 -
mid- C3 Midpoint. 29 39 85 91 100 -
points C4 Bottom west. 29 39 87 92 98 -
C5 Bottom east. 29 38 89 90 96 -
C6 50 mm above latch. 29 56 84 95 116 -
Misc. C7 Top west corner. 29 43 84 93 100 -
C8 West at mid-height. 29 49 70 85 94 -
C9 Upper west corner. 29 35 62 68 72 -
C10 Mid-width of door leaf. 29 34 59 69 77 -
Timber
frame C11 Upper east corner. 29 47 58 73 77 -
C12 East at mid-height. 29 36 67 83 91 -
1
Notes: Limit time is the time to the nearest whole minute, rounded down to the nearest minute, at which
the temperature recorded by the thermocouple does not rise by more than 180K above the initial
temperature.
2
Refer to Appendix 3 for locations of thermocouples as only a generic description is included in the
table.
‘-’ Under limit column indicates the temperature limit was not exceeded during the reported period or
up until the time of integrity failure if a failure occurred.
# Faulty thermocouple

Page 33 of 39
Table A4.2: Quarter and centre point average temperature limits of Doorsets.
Temp (°C) at t (minutes) Limit1
Doorset
t=0 t=30 t=60 t=75 t=79 (Mins)
Doorset A 29 40 85 - - -
Doorset B 29 39 86 93 107 -
1
Notes: Limit time is the time to the nearest whole minute, rounded down to the nearest
minute, at which the average temperature recorded by the thermocouples
(quarter points) does not rise by more than 140K above the initial average
temperature.
2
Refer to Appendix 3 for locations of thermocouples as only a generic description
is included in the table.
‘-’ Under limit column indicates the temperature limit was not exceeded during the
reported period or up until the time of integrity failure if a failure occurred.

Page 34 of 39
A 4.4 DEFLECTION MEASUREMENTS
25
20
15
10
Deflection (mm)
5
0
-5
-10
-15
-20
-25
-30
-35
-40
0 15 30 45 60 75 90
Time (Minutes)
DA1 DAF1 DAC DA2 DAF2
Figure A4.10: Out-of-Plane Deflection vs. Time of Doorset A.

Positive measurements show movement of doorset towards furnace and
negative measurements show movement of doorset away from furnace.
25
20
15
10
Deflection (mm)
5
0
-5
-10
-15
-20
-25
-30
-35
-40
0 15 30 45 60 75 90
Time (Minutes)
DB1 DBF1 DBC DB2 DBF2
Figure A4.11: Out-of-Plane Deflection vs. Time of Doorset B.

Positive measurements show movement of doorset towards furnace and
negative measurements show movement of doorset away from furnace.

Page 35 of 39
A 4.5 HEAT FLUX MEASUREMENT
5.0
4.5
4.0
Irradiance (kW/m²)
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
0 15 30 45 60 75 90
Time (Minutes)
Recorded Radiation Emitted Radiation Integrity Limit
Figure A4.12: Heat flux emitted from Doorset A vs Time

Radiometer located central to the door leaf at 1000 mm away from the specimen.
Recorded radiation is radiation level at radiometer position and emitted radiation is
radiation level (calculated) emitted from face of door leaf
5.0
4.5
4.0
Irradiance (kW/m²)
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
0 15 30 45 60 75 90
Time (Minutes)
Recorded Radiation Emitted Radiation Integrity Limit
Figure A4.13: Heat flux emitted from Doorset B vs Time

Radiometer located central to the door leaf at 1000 mm away from the specimen.
Recorded radiation is radiation level at radiometer position and emitted radiation is
radiation level (calculated) emitted from face of door leaf

Page 36 of 39
APPENDIX 5 PHOTOGRAPHS
Door B Door A
Figure A5.1: Exposed face of test specimen prior to commencement of test
Door A Door B
Figure A5.2: Unexposed face of test specimen prior to commencement of test

Page 37 of 39
Figure A5.3: Unexposed face of test specimen after approximately

60 minutes test duration
Figure A5.4: Integrity failure of Doorset A after approximately

65 minutes test duration (sustained flaming for longer than 10 seconds)

Page 38 of 39
Figure A5.5: Unexposed face of test specimen prior to

(approximately 1 minute prior) completion of test
Figure A5.6: Unexposed face of test specimen after completion of test

Page 39 of 39
Figure A5.7: Exposed face of test specimen after the completion of test

Kingsa 60mts Body Cote - Unlocked

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Title:

Fire Resistance test of two single

BWA Report No:

14th March 2008

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

DOCUMENT REVISION STATUS

Date Issued Issue No Description

2nd April 2008 2250900a.1 Initial issue

Prepared by: Reviewed by:

On behalf of Bodycote Warringtonfire (Aus) Pty Ltd

GENERAL CONDITIONS OF USE

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

ASSEMBLY AND INSTALLATION METHODS

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

VARIATIONS FROM TEST STANDARDS

SAMPLING / SPECIMEN SELECTION

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

INSTRUMENTATION AND EQUIPMENT

FURNACE TEMPERATURE AND PRESSURE MEASUREMENTS

HEAT FLUX MEASUREMENT

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

Loadbearing Capacity Not applicable

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

6 APPLICATION OF TEST RESULTS

VARIATIONS FROM THE TESTED SPECIMENS

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

APPENDIX 1 DRAWINGS OF TEST ASSEMBLY

hollow concrete blocks

Lintel with 1-off D16 rod

Every third course

mortar joint with

14-off blocks turned

UNEXPOSED FACE ELEVATION

Figure A1.1: Masonry Wall Elevation

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

Lorient Intumescent Mastic over

UNEXPOSED FACE ELEVATION

Figure A1.2: Test Specimen Elevation

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

Door Frame 901mm Overall

Door Leaf width 826mm Overall

Door Leaf Height 2040mm Overall

Specialising in Fire, Sm oke, Acoustic

Figure A1.3: Doorset Constructional Drawing (Provided By Client)

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

DANUBE KINGSA 60 VERTICAL

S p e c ia lisin g in F ire , S m o ke , A co u s tic

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

DANUBE KINGSA 60 HORIZONTAL

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

Figure A1.6: Doorset Hinge Details (Provided By Client)

DANUBE KINGSA 60 HINGE

© Bodycote Warringtonfire (Aus) Pty Ltd 2008

DANUBE KINGSA 60 INTUMESCENT

Figure A1.7: Doorset Intumescent Strip locations (Provided By Client)

Figure A1.8: Lorient Intumescent Kit (Provided By Client)