Durasteel Valve Enclosures ensure safe operational access at chemical storage facilityLocation: Dubai, UAEImage Gallery Be...
Fire Barriers installed in underground tunnels at Jebel Ali Desalination PlantLocation: Dubai, UAEImage Gallery BelowThe w...
GalleryDurasteel Ceilings and Cable Turning Box Protect EDF SubstationLocation: London, UKImage Gallery BelowThrogmorton S...
Demountable EDF Energy Transformer Blast BarriersLocation: London, UKImage Gallery BelowInvictas Durasteel division has re...
Location: UKImage Gallery BelowInvicta has recently completed the design and installation of 3 self-supportingtransformer ...
of paper documents, the Council decided to relocate its document storage facility to anew, larger warehouse and within it ...
Crown Records Management install custom designed Durasteel fireproof vaultLocation: London, UKImage Gallery BelowThe backi...
Laboratories Canada (ULC), Det Norske Veritas (DNV), Lloyds Register of Shipping (LRS),Zulassung, EDF and LUL. In addition...
Durasteel Suspended Ceiling Membrane E240 (Fire from Aboveand Below)   •   Fire resistance: 240 minutes integrity only (Fi...
ensure appropriate penetration of screw thread in accordance with screwmanufacturers recommendations. Longitudinal board j...
Perimeter channels of ceiling membrane fastened to surrounding construction with M10or M12 all steel expanding anchors (or...
As drop rods support the ceiling, the length and width of ceiling membrane isunrestrictedDurasteel Suspended Ceiling Membr...
Longitudinal and transverse channel members are either welded together or joined withsteel angle cleats, minimum 60mm x 60...
Perimeter channels of ceiling membrane fastened to surrounding construction with M10or M12 allsteel expanding anchors (or ...
On one side of the expansion gap the primary and jointing channels are connected withminimum two M10 bolts. On the opposit...
9.5mm Durasteel fillet strips fitted over the upper and lower faces of the channelmembers. Fillets must overlap the channe...
IntroductionThis Durasteel composite membrane plenum ceiling may be constructed as aselfsupporting membrane for areas up 3...
MF5 ceiling sections (5) are installed perpendicular to the Durasteel framing at 625mmcentres, with MF6 (6) channel at the...
Transverse 80mm x 60mm x 3mm CRC (3) are cleated between the primary channels,coincident with the Durasteel board ends.9.5...
Ironmongery   •   Standard weight counterbalance system, heavy duty mild steel trackCertification   •   BS 476: Part 22: 1...
Overall frame length     D (B + 96 = D)         996mmDoor leaf width          E ((B + D + 92 = E)    1988mmDoor leaf heigh...
Perimeter channels fastened to surrounding construction with M10 or M12 all-steelexpanding anchors (or equivalent for alte...
•   Estimated sound reduction: 42dBPerimeter channels fastened to surrounding construction with M10 or M12 all-steelexpand...
Back to back channels fastened together with M10 steel bolts and nuts at 500mmmaximum centres. The vertical joints in the ...
If the rock wool does not fill the cavity, it must be fastened into position with 2.5mm-diameter steel stud-welded pins an...
The vertical channels are set at a maximum 1200mm centres. Horizontal and verticalchannel members either welded together o...
Please note that the following Durasteel system connection details are examples only.Connection details for each system wi...
Sheet Join Interface   1.   150mm x 60mm x 3mm CRC Frame Back To Back   2.   M10 x 25mm Bolts c/w Nut and Washer   3.   15...
6. 15mm Promatect 250Pipe Penetration Interface   1.   150mm x 60mm x 3mm CRC Frame   2.   9.5mm Durasteel Sheet   3.   15...
Cleating - Corner Interface Elevation View   1.   150mm x 60mm x 3mm CRC Frame   2.   9.5mm Durasteel Sheet   3.   M10 x 2...
Cleating - Perimeter Interface Elevation View   1.   150mm x 60mm x 3mm CRC Frame   2.   9.5mm Durasteel Sheet   3.   M10 ...
2.   M10 x 25mm Hex HD Bolts or M10 x 20mm CSK HD Bolts c/w Nut and Washer   3.   150mm x 60mm x 3mm CRC Frame   4.   2 No...
Cleating - Internal Interface Section View   1.   M10 x 20mm CSK HD Bolts c/w Nut and Washer   2.   150mm x 60mm x 3mm CRC...
Suspended Movement Head Detail  1.   Profile Cut and Seal to Purlins  2.   Curved 150mm x 60mm x 3mm CRC Head Channel  3. ...
Standard Movement Head Detail  1.   Profile Cut and Seal to Purlins  2.   Curved 200mm x 60mm x 3mm CRC Head Channel  3.  ...
Wall Fixing   1.   Dwarf Wall   2.   Existing Plasterboard Wall   3.   Mastic   4.   Mastic   5.   150mm x 60mm x 3mm CRC ...
Roller Shutter Steelwork Fixing   1.   50mm x 50mm x 3mm Angle   2.   150mm x 60mm x 3mm CRC Frame Back To Back   3.   M10...
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Durasteel projects ref..

  1. 1. Durasteel Valve Enclosures ensure safe operational access at chemical storage facilityLocation: Dubai, UAEImage Gallery BelowDOW Chemical Companys chemical storage facility in Dubai recently identified a safetyrequirement to protect the main deluge valves within a chemical storage area frompotential fire and explosions. The valves were located in an open and exposed areaadjacent to the main chemical storage facility.Tasked with designing 3-sided Durasteel barriers which had to be completely free-standing, wind resistant and weather-proof, and maintain their integrity withinpotentially harsh chemical atmospheric conditions.Our solution was to build free-standing Durasteel valve protection enclosuresconstructed from 80mm x 60mm x 3mm steel channels with a single sheet of Durasteelbolted to the exterior surface.Each enclosure was completely installed within 1.5 days from start to finish and nowprovides the valves with the blast and fire protection required to ensure continued andsafe operational access in the event of a fire or explosion.Site supervisor, Louie Aguilar, commented "it was a very fast installation, completedincredibly quickly by a very professional team and we are extremely pleased with theoutcome."Gallery
  2. 2. Fire Barriers installed in underground tunnels at Jebel Ali Desalination PlantLocation: Dubai, UAEImage Gallery BelowThe worlds largest desalination plant, the Dubai Electricity and Water Authority (DEWA)Jebel Ali Desalination Plant located in Dubai, which has an electrical capacity of2,000MW and purifies around 480 million litres of seawater daily, has recently hadDurasteel extensively installed across the facility by our Middle East division.Underground tunnels and cable routes run across the entire desalination site,connecting various buildings at below-ground level and housing cables vital to theoperation of the plant. In order to isolate these tunnels and buildings from any potentialfire hazards, site consultant, Fichtner Consulting Engineers, and main site contractor,Doosan Heavy Industries and Construction, decided that fire barriers were an essentialrequirement in the tunnels in order to maximise safety, contain the spread of fire andlimit the damage caused in the event of a fire occurring.The requirement was to construct fire barriers to provide effective compartmentation inthe following typical locations: • Between building basements and cable trenches/tunnels • Between cable trenches and cable tunnels • Between trenches and escape routes (ladders) and exitsIt was identified that fire barriers were required at 79 separate tunnel locations acrossthe site in order to effectively isolate a fire occurring within the tunnels, and that eachbarrier must provide 2 hour fire protection and withstand high numbers of dooropenings and closures every day, in addition to being fully demountable andrelocatable. The size of the fire barrier at each location was designed to be 2.80m wide x2.20m high, with each fire barrier containing one 2 hour fire rated access door and cut-out provisions for 6 cable trays on each side of the door to pass through the fire barrier,with the penetrations being filled with firebat.Working in harsh underground conditions and with extremely limited manoeuvringspace, each Durasteel barrier was installed in phases, with provisions for cable pullingand fixing of the access fire doors at a later stage. Erection of each complete barrier,including the fire doors and penetration sealing, took less than 2 working days fromstart to finish.With the project deemed a success, Durasteel was then specified for use on the samesite as removable generator barriers.
  3. 3. GalleryDurasteel Ceilings and Cable Turning Box Protect EDF SubstationLocation: London, UKImage Gallery BelowThrogmorton Street in London is a commercial retail outlet which has recentlyundergone a complete refurbishment and an EDF substation installed into the basementarea.Invictas Durasteel division were asked to design and install a Durasteel 4 hour fire ratedcable turning box complete with demountable panels to allow access by EDF engineers,with blastproof fire morter on all penetrations.Additionally, Invicta also designed and installed 2 independent Durasteel 4 hour firerated ceilings to the substation and switch rooms in the basement to protect the officesabove from any explosions originating from the high voltage cables and transformerslocated in the rooms. The ceilings were approximately 12m² and 25m² in size andincluded a rake detail to deflect any blast out through the louvre in each room.The entire project was installed from start to finish in 3 weeks.Related pages: Fireproof Ceilings, Substation Ceiling Fire ProtectionGallery
  4. 4. Demountable EDF Energy Transformer Blast BarriersLocation: London, UKImage Gallery BelowInvictas Durasteel division has recently completed the installation of 4 demountableEDF Energy blast barriers to give blast protection of up to 10kN/m² at a substationdemolition site in London.Due to the limited working space on site, the 4 2.5 tonne Durasteel blast barriers werefully pre-fabricated and then lifted and secured into position using a crane. The blastbarriers were designed and installed to protect personnel working on the demolitionsite from the potential explosions of 4 transformers located in the immediate vicinity.The barriers are fully demountable within 4 hours in the event of a transformer failingand the barrier requiring removal in order to allow access to the transformer.The project was completed from start to finish in less than 5 weeks and the blastbarriers comply with stringent EDF Energy specifications.Related pages: Transformer Barriers, Blast WallsGalleryTransformer Blast Barriers provide blast protection to Fertiliser Plant
  5. 5. Location: UKImage Gallery BelowInvicta has recently completed the design and installation of 3 self-supportingtransformer blast barriers at a fertiliser plant in the UK.The 4.2m x 4.5m blast barriers were designed bespoke to provide 10kN/m² blastprotection, with welded steel bracing supports in order to provide the barriers withincreased stability to cater for the additional blast protection and wind loadings in thearea. The 3 blast barriers were installed in order to prevent a chain blast occurringshould one of the 4 transformers in the area explode.Installation of all 3 blast barriers was completed in less than 3 weeks, much of whichtook place in some of the most severe snow and ice conditions the UK has experiencedin the last century. However, with Invictas vast experience in designing, projectmanaging and installing Durasteel, these conditions were overcome and the project wascompleted on time.Related pages: Transformer Barriers, Blast ProtectionGalleryFireproof Vault Protects Council RecordsLocation: Staffordshire, UKImage Gallery BelowStaffordshire County Council in the UK serves a population of around 800,000 residentswith vital services to the community, including schools, libraries, social services, tradingstandards, highways and planning. With all of these services generating large numbers
  6. 6. of paper documents, the Council decided to relocate its document storage facility to anew, larger warehouse and within it include a fireproof vault for the storage of the mostimportant documents.Invicta were asked to design and install a 35m long x 7m wide x 5m tall vault, filled tocapacity with mobile shelving to maximise the vaults storage space. The vault wasengineered and designed to be completely self-supporting, without any internal orexternal structural support columns and beams that would normally also require fireprotecting.Providing industry leading 4 hour fire protection, the vault had air conditioning and awater leak detection system installed to ensure complete protection from not only firebut also moisture and water that could also potentially damage the documents inside.A mantrap lobby was constructed on the outside of the vaults main entry door toensure that the ideal ambient temperature could be constantly maintained inside thevault even when doors were opened. All entry doors were secured with magnetic lockPIN entry systems to prevent unauthorised access to the vault and sensitive documents.The vault installation was completed in under 8 weeks before the remaining space in thewarehouse was filled with pallet racking for the storage of the Councils non-sensitivedocuments.Related pages: Fireproof VaultGallery
  7. 7. Crown Records Management install custom designed Durasteel fireproof vaultLocation: London, UKImage Gallery BelowThe backing up of business-critical data is widely regarded as being one of the mostimportant processes a business can do and is a fundamental element of any businesscontinuity plan. Yet research suggests that up to 75% of backup tapes are kept on-site,meaning that in the event of a disaster, any business continuity plan that may be inplace will be rendered useless. On average, by the 6th day of a major data loss,companies experience a 25% loss in daily revenue, and by day 25, this increases to 40%.It is also estimated that 43% of companies that experience a severe data loss disasternever re-open.In response to increasing customer demands driven by the recent surge in both naturaldisasters and man-made threats around the world, Crown Records Managementdecided to have a custom designed Invicta Durasteel vault installed at one of theirrecords storage facilities in the UK, providing clients with an industry-leading 4 hour fireprotected facility for the secure storage of their business-critical data tapes andirreplaceable documents.The challenge faced by Invicta was to design and integrate the media and documentvault within a large multi-tier racking system without compromising on any loss of spaceutilisation within the cube of Crowns building. Invictas solution was to build a 630square metre, 4-tier Durasteel vault in one corner of the warehouse to a height of 12metres. Durasteel is a 4 hour fire rated product that has been tested extensively in theUK to comply to all relevant parts of BS 476, as well as many international standardssuch as Factory Mutual (FM), Underwriters Laboratories Inc (UL), Underwriters
  8. 8. Laboratories Canada (ULC), Det Norske Veritas (DNV), Lloyds Register of Shipping (LRS),Zulassung, EDF and LUL. In addition to providing superior protection from fire, Durasteelalso provides impact and moisture protection, both of which are essential, but oftenoverlooked, features for vaults located within buildings surrounded by other structuresthat may fall onto it and building services that may fail in the event of a disaster.Durasteel has also achieved the stringent Certifire approvals and was therefore installedon the underside of each level of the vault to provide an independent 4 hour fire ratedcompartment to each floor level. Mobile shelving was installed on the ground floor,specifically designed for the optimal storage of over 27,000 data tapes, whilst the upperthree levels of the vault were equipped with racking for the secure storage of over 6000boxes.Crowns vault was completed with state-of-the-art climate control and gas suppressionsystems in order to regulate a constant environment, and was then smoke and pressuretested in order to certify its performance.Related pages: Fireproof VaultsGallery
  9. 9. Durasteel Suspended Ceiling Membrane E240 (Fire from Aboveand Below) • Fire resistance: 240 minutes integrity only (Fire attack from above or below) • Channel (minimum): 80mm x 60mm x 3mm • Overall depth: 89.5mm • Weight (nominal): 27kg/m2Perimeter channels of ceiling membrane fastened to surrounding construction with M10or M12 allsteel expanding anchors (or equivalent for alternative types of supportingconstruction) at 500mm maximum centres.Primary channels at 1200mm maximum centres, supported from building structureabove the ceiling membrane with steel drop rods at 1.5m centres. Threaded rods passthrough clearance holes in the upper flange of the channels and are fastened with steelhexagon full nuts.Diameter of drop rods such that the tensile stress within the rods does not exceed6N/mm2 for fire ratings up to 240 minutes. (This may be increased to 10N/mm2 if only a120 minutes fire rating is required).9.5mm 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 12mm fromedge of sheet and a maximum of 50mm from corners. Length of fixing to be sufficient to
  10. 10. ensure appropriate penetration of screw thread in accordance with screwmanufacturers recommendations. Longitudinal board joints coincide with primarychannels, transverse board joints backed by steel channel the same size as the primarychannels. Longitudinal and transverse channel members are either welded together orjoined 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.Where an expansion allowance is provided within the primary channels, steel jointingchannels, minimum 50mm flanges x 3mm thick, are fastened to the primary channelswith M10 steel bolts and nuts. The width of the jointing channel (web dimensions)should be such that it is a close fit within the primary channels.On one side of the expansion gap the primary and jointing channels are connected withminimum two M10 bolts. On the opposite side the channels are connected, throughslotted holes, with minimum two M10 bolts fitted with fusible washers.For fire attack from below, an expansion allowance of at least 6mm per metre isrequired for primary channels longer than 4m.For fire attack from above, an expansion allowance of at least 6mm per metre isrequired for all sizes of ceiling. As drop rods support the ceiling, the length and width ofceiling membrane is unrestricted.Durasteel Suspended Ceiling Membrane E240 EI120 (fire frombelow)Print This Page Email This Page Bookmark This Page • Fire resistance: 240 minutes integrity 120 minutes insulation (Fire attack from below) • Channel (minimum): 80mm x 60mm x 3mm • Overall depth: 108.5mm • Weight (nominal): 42kg/m2
  11. 11. Perimeter channels of ceiling membrane fastened to surrounding construction with M10or M12 all steel expanding anchors (or equivalent for alternative types of supportingconstruction) at 500mm maximum centres.Primary channels at 1200mm maximum centres, supported from building structureabove the ceiling membrane with steel drop rods at 1.5m centres. Threaded rods passthrough clearance holes in the upper flange of the channels and are fastened with steelhexagon full nuts.Diameter of drop rods such that the tensile stress within the rods does not exceed6N/mm2 for fire ratings up to 240 minutes. (This may be increased to 10N/mm2 if only a120 minutes fire rating is required).9.5mm Durasteel fillet strips fitted over the upper and lower faces of the channelmembers. Fillets must overlap the channels by at least 20mm on both sides.9.5mm Durasteel boards fastened (through fillet strips) to lower flange of steel channelswith M5.5 steel self-drill and tap Tek screws at 200mm nominal centres. Fixings aminimum of 12mm from edge of sheet and a maximum of 50mm from corners. Lengthof fixing to be sufficient to ensure appropriate penetration of screw thread inaccordance with screw manufacturers recommendations.Longitudinal board joints coincide with primary channels, transverse board joints backedby steel channel the same size as the primary channels.Longitudinal and transverse channel members are either welded together or joined withsteel angle cleats, minimum 60mm x 60mm x 3mm thick x 60mm long, fastened to eachchannel member with two M10 steel bolts and nuts.Rock wool insulation 80mm x 140 kg/m3 nominal density, fitted over the soffit layer ofDurasteel by filling the channels. Joints in layers of rock wool overlap by at least 150mm.Where an expansion allowance is provided within the primary channels, steel jointingchannels, minimum 50mm flanges x 3mm thick, are fastened to the primary channelswith M10 steel bolts and nuts. The width of the jointing channel (web dimensions)should be such that it is a close fit within the primary channels.On one side of the expansion gap the primary and jointing channels are connected withminimum two M10 bolts. On the opposite side the channels are connected, throughslotted holes, with minimum two M10 bolts fitted with fusible washers.For fire attack from below, an expansion allowance of at least 6mm per metre isrequired for primary channels longer than 4m.
  12. 12. As drop rods support the ceiling, the length and width of ceiling membrane isunrestrictedDurasteel Suspended Ceiling Membrane EI120 (fire from aboveor below)Print This Page Email This Page Bookmark This Page • Fire resistance: 120 minutes integrity and insulation (Fire from above or below) • Channel (minimum): 80mm x 60mm x 3mm • Overall depth: 166mm • Weight (nominal): 34kg/m2Perimeter channels of ceiling membrane fastened to surrounding construction with M10or M12 all steel expanding anchors (or equivalent for alternative types of supportingconstruction) at 500mm maximum centres.Primary channels at 1200mm maximum centres, supported from building structureabove the ceiling membrane with steel drop rods at 1.5m centres. Threaded rods passthrough clearance holes in the upper flange of the channels and are fastened with steelhexagon full nuts.Diameter of drop rods such that the tensile stress within the rods does not exceed10N/mm2.6 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 12mm fromedge of sheet and a maximum of 50mm from corners. Length of fixing to be sufficient toensure appropriate penetration of screw thread in accordance with screwmanufacturers recommendations. Longitudinal board joints coincide with primarychannels, transverse board joints backed by steel channel the same size as the primarychannels.
  13. 13. Longitudinal and transverse channel members are either welded together or joined withsteel angle cleats, minimum 60mm x 60mm x 3mm thick x 60mm long, fastened to eachchannel member with two M10 steel bolts and nuts.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.Where an expansion allowance is provided within the primary channels, steel jointingchannels, minimum 50mm flanges x 3mm thick, are fastened to the primary channelswith M10 steel bolts and nuts. The width of the jointing channel (web dimensions)should be such that it is a close fit within the primary channels.On one side of the expansion gap the primary and jointing channels are connected withminimum two M10 bolts. On the opposite side the channels are connected, throughslotted holes, with minimum two M10 bolts fitted with fusible washers.For fire attack from below, an expansion allowance of at least 6mm per metre isrequired for primary channels longer than 4m.For fire attack from above, an expansion allowance of at least 6mm per metre isrequired for all sizes of ceiling.As drop rods support the ceiling, the length and width of ceiling membrane isunrestricted.Durasteel Suspended Ceiling Membrane EI240 (fire from aboveor below - method 1)Print This Page Email This Page Bookmark This Page • Fire resistance: 240 minutes integrity & insulation. (Fire attack from above or below) • Channel (minimum): 80mm x 60mm x 3mm • Overall depth: 151mm • Weight (nominal): 55kg/m2
  14. 14. Perimeter channels of ceiling membrane fastened to surrounding construction with M10or M12 allsteel expanding anchors (or equivalent for alternative types of supportingconstruction) at 500mm maximum centres.Primary channels at 1200mm maximum centres, supported from building structureabove the ceiling membrane with steel drop rods at 1.5m centres. Threaded rods passthrough clearance holes in the upper flange of the channels and are fastened with steelhexagon full nuts.Diameter of drop rods such that the tensile stress within the rods does not exceed6N/mm2 for fire ratings up to 240 minutes.9.5mm 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 12mm fromedge of sheet and a maximum of 50mm from corners. Length of fixing to be sufficient toensure appropriate penetration of screw thread in accordance with screwmanufacturers recommendations.Longitudinal board joints coincide with primary channels, transverse board joints backedby steel channel the same size as the primary channels. Longitudinal and transversechannel members are either welded together or joined with steel angle cleats, minimum60mm x 60mm x 3mm thick x 60mm long, fastened to each channel member with twoM10 steel bolts and nuts.Rock wool insulation, total of 120mm x 140 kg/m3 nominal density fitted with 2 x 60mmthick layers, one layer fitted over the Durasteel soffit layer by filling the channels andthe second layer fitted over channels. Joints in layers of rock wool overlap by at least150mm.A layer of 1.5mm thick steel sheet is laid on top of the upper layer of rock wool. Wherean expansion allowance is provided within the primary channels, steel jointing channels,minimum 50mm flanges x 3mm thick, are fastened to the primary channels with M10steel bolts and nuts. The width of the jointing channel (web dimensions) should be suchthat it is a close fit within the primary channels.
  15. 15. On one side of the expansion gap the primary and jointing channels are connected withminimum two M10 bolts. On the opposite side the channels are connected, throughslotted holes, with minimum two M10 bolts fitted with fusible washers. For fire attackfrom below, an expansion allowance of at least 6mm per metre is required for primarychannels longer than 4m.For fire attack from above, an expansion allowance of at least 6mm per metre isrequired for all sizes of ceiling.As drop rods support the ceiling, the length and width of ceiling membrane isunrestricted.Durasteel Suspended Ceiling Membrane EI240 (fire from aboveor below - method 2)Print This Page Email This Page Bookmark This Page • Fire resistance: 240 minutes integrity & insulation. (Fire attack from above or below) • Channel (minimum): 60mm x 150mm x 60mm x 3mm • Overall depth: 188mm • Weight (nominal): 75kg/m2Perimeter channels of ceiling membrane fastened to surrounding construction with M10or M12 all steel expanding anchors (or equivalent for alternative types of supportingconstruction) at 500mm maximum centres.Primary channels at 1200mm maximum centres, supported from building structureabove the ceiling membrane with steel drop rods at 1.5m centres. Threaded rods passthrough clearance holes in the upper flange of the channels and are fastened with steelhexagon full nuts.Diameter of drop rods such that the tensile stress within the rods does not exceed6N/mm2 for fire ratings up to 240 minutes.
  16. 16. 9.5mm Durasteel fillet strips fitted over the upper and lower faces of the channelmembers. Fillets must overlap the channels by at least 20mm on both sides.9.5mm Durasteel boards fastened (through fillet strips) to upper and lower flange ofsteel channels with M5.5 steel 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 inaccordance with screw manufacturers recommendations.Longitudinal board joints coincide with primary channels, transverse board joints backedby steel channel the same size as the primary channels.Longitudinal and transverse channel members are either welded together or joined withsteel angle cleats, minimum 60mm x 60mm x 3mm thick x 60mm long, fastened to eachchannel member with two M10 steel bolts and nuts.Rock wool insulation 150mm x 140 kg/m3 nominal density, fitted over the soffit layer ofDurasteel by filling the channels. Joints in layers of rock wool overlap by at least 150mm.Where an expansion allowance is provided within the primary channels, steel jointingchannels, minimum 50mm flanges x 3mm thick, are fastened to the primary channelswith M10 steel bolts and nuts. The width of the jointing channel (web dimensions)should be such that it is a close fit within the primary channels.On one side of the expansion gap the primary and jointing channels are connected withminimum two M10 bolts. On the opposite side the channels are connected, throughslotted holes, with minimum two M10 bolts fitted with fusible washers. For fire attackfrom below, an expansion allowance of at least 6mm per metre is required for primarychannels longer than 4m.For fire attack from above, an expansion allowance of at least 6mm per metre isrequired for all sizes of ceiling.As drop rods support the ceiling, the length and width of ceiling membrane isunrestricted.Durasteel Composite Membrane Plenum Ceiling E240 EI60 (Firefrom Below)Print This Page Email This Page Bookmark This Page
  17. 17. IntroductionThis Durasteel composite membrane plenum ceiling may be constructed as aselfsupporting membrane for areas up 3m x 2m (maximum span 3m); or as a suspendedceiling system with hangers coincident with the longitudinal framing channels at1500mm centres.Promat Promatect -250 panels, fitted to underside of the Durasteel ceiling, contribute tothe fire insulation performance of the system, and also provide a fair face to the ceiling.ConstructionSelf Supporting Ceiling Option: Weight (nominal) 37kg/m2The maximum area as a self supporting ceiling (supported on all four edges) is 3m x 2m.Perimeter framing (1) of 80mm x 60mm x 3mm CRC is fastened to surroundingconstruction with M10 or M12 all-steel expanding anchors (or equivalent for alternativetypes of supporting construction), at 500mm maximum centres.Supporting channels (2) in 80mm x 60mm x 3mm CRC at 1200mm maximum centres areeither welded to the perimeter framing or joined using 120 x 60 x 3mm angled cleatsfastened to each channel member with two M10 steel bolts and nuts. Transverse 80mmx 60mm x 3mm CRC (3) are installed coincident with the Durasteel end of board joints.9.5mm Durasteel (4) is fastened to the underside of the framing using 38mm TEK screwsfixed at 200mm centres.
  18. 18. MF5 ceiling sections (5) are installed perpendicular to the Durasteel framing at 625mmcentres, with MF6 (6) channel at the ceiling perimeter fastened to the walls. The MF5grid system is fastened to the CRC framework through the Durasteel panels, and to theunderside of Durasteel ceiling using 38mm TEK screws at 400mm centres.A 15mm Promatect -250 ceiling lining (7) is fastened to the MF grid system using 32mmDrywall screws at 200mm centres. (Screws are to be inserted 15mm from the boardedge, and 40mm from the corner of the board).Note: Promatect -250 boards are installed parallel to the Durasteel panels (and at rightangles to the MF5 ceiling sections), but with staggered joints in both directions betweenlayers.100mm wide Promatect -250 cover strips (8) are fastened behind the transverse jointsbetween the MF5 sections of the Promatect -250 boards, using 32mm drywall screws atnominal 250mm centres, with the screws at 25mm from edge of the board, and 50mmfrom ends of the cover strips.Suspended Ceiling Option: Weight (nominal): 37kg/m2Perimeter framing of 80mm x 60mm x 3mm CRC (1) is fastened to surroundingconstruction with M10 or M12 all-steel expanding anchors (or equivalent for alternativetypes of supporting construction) at 500mm maximum centres.Primary channels of 80mm x 60mm x 3mm CRC (2) at 1200mm maximum centresfastened to the perimeter and suspended from the building structure above the ceilingmembrane using steel drop rods at maximum 1.5m centres. The threaded rods passthrough clearance holes in the upper fl ange of the channels, and are fastened with steelhexagon full nuts.The diameter of the hanger rods are such sized so that the tensile stress within the rodsdoes not exceed 6N/mm2.An expansion allowance of at least 6mm per metre is required for primary channelslonger than 4m.Where an expansion allowance is provided within the primary channels, steel jointingchannels (minimum 50mm fl anges x 3mm thick) are fastened to the primary channelswith M10 steel bolts and nuts. The width of the jointing channel (web dimensions)should be such that it is a close fit within the primary channels.On one side of the expansion gap the primary and jointing channels are connected withminimum two M10 bolts. On the opposite side the channels are connected, throughslotted holes, with minimum two M10 bolts fitted with fusible washers.
  19. 19. Transverse 80mm x 60mm x 3mm CRC (3) are cleated between the primary channels,coincident with the Durasteel board ends.9.5mm Durasteel (4) is fastened to the underside of the framing using 38mm TEK screwsfixed at 200mm centres.MF5 ceiling sections (5) are installed perpendicular to the Durasteel framing at 625mmcentres, with MF6 (6) channel at the ceiling perimeter fastened to the walls. The MF5grid system is fastened to the CRC framework through the Durasteel panels, and to theunderside of Durasteel ceiling using 38mm TEK screws at 400mm centres.A 15mm Promatect -250 ceiling lining (7) is fastened to the MF grid system using 32mmDrywall screws at 200mm centres. (Screws are to be inserted 15mm from the boardedge, and 40mm from the corner of the board).Note: Promatect -250 boards are installed parallel to the Durasteel panels (and at rightangles to the MF5 ceiling sections), but with staggered joints in both directions betweenlayers. 100mm wide Promatect -250 cover strips (8) are fastened behind the transversejoints between the MF5 sections of the Promatect -250 boards, using 32mm drywallscrews at nominal 250mm centres, with the screws at 25mm from edge of the board,and 50mm from ends of the cover strips. Since drop-rods support the ceiling, the lengthand width of ceiling membrane is unrestricted.Durasteel DD120 and DD240 Fire ShuttersPrint This Page Email This Page Bookmark This PageLeaf • Overall Thickness: 12mm (DD120) 28mm (DD240) • Material: 9.5mm thick Durasteel sheet • Jointing Construction: Mitred and WeldedFrame • Overall Frame Depth: 80mm • Material: 45 x 80 x 45 x 6mm thick Z-section/25 x 15 x 3mm thick angle section • Jointing: Mitred and Welded joints • Type and Configuration: 3-sided frame with trailing edge flame trapFinish • Frame and Leaf: Standard shop applied zinc based primer, ready for site painting (P3)
  20. 20. Ironmongery • Standard weight counterbalance system, heavy duty mild steel trackCertification • BS 476: Part 22: 1987Dimensional Details Ref Single Leaf Doorset Example CalculationStructural opening width A A 920mmStructural opening height B B 900mmOverall frame width C (A + 92 = C) 1012mm
  21. 21. Overall frame length D (B + 96 = D) 996mmDoor leaf width E ((B + D + 92 = E) 1988mmDoor leaf height F (A + 178 = F) 1098mmDurasteel Fire Barrier E240 Integrity OnlyPrint This Page Email This Page Bookmark This Page • 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
  22. 22. Perimeter channels fastened to surrounding construction with M10 or M12 all-steelexpanding anchors (or equivalent for alternative types of supporting construction) at500mm maximum centres.The vertical channels are set at a maximum 1200mm centres. Horizontal and verticalchannel members either welded together or joined with steel angle cleats, minimum60mm x 60mm x 3mm thick x 60mm long, fastened to each channel member with twoM10 steel bolts and nuts.A single layer of 9.5mm Durasteel fixed on one side of channel with M5.5 steel self drilland tap Tek screws at 250mm nominal centres. Fixings a minimum of 12mm from edgeof sheet and a maximum of 50mm from corners. Length of fixing to be sufficient toensure appropriate penetration of screw thread in accordance with screwmanufacturers recommendations.Vertical board joints coincide with studs, horizontal board joints are backed by steelchannel the same size as the vertical studs.Expansion allowance will be required for barriers above 4 metres high. Please contact usfor further information.Steel channel sizes for barrier heights up to 15 metresHeight of Barrier (m) Channel size (mm x mm x mm) Estimated Sound Insulation Rw (dB)0-6 80 x 60 x 3 336-9 150 x 60 x 3 339 - 12 Two 150 x 60 x 3 Back to back 3312 - 15 Two 175 x 60 x 3 back to back 33Back to back channels fastened together with M10 steel bolts and nuts at 500mmmaximum centres. The vertical joints in the Durasteel should be offset by 30mm fromthe centreline of the back-to-back studs, to avoid a straight through path for hot gases.Horizontal channels are single channels.Durasteel Fire Barrier E240 EI60Print This Page Email This Page Bookmark This Page • Fire resistance: 240 minutes integrity - 60 minutes insulation (Fire attack from either face) (Formally referred to as the STI 240/60 System) • Channel (minimum): 80mm x 60mm x 3mm (for heights up to 6m) • Overall width: 118mm • Weight (nominal): 51kg/m2
  23. 23. • Estimated sound reduction: 42dBPerimeter channels fastened to surrounding construction with M10 or M12 all-steelexpanding anchors (or equivalent for alternative types of supporting construction) at500mm maximum centres.The vertical channels are set at a maximum 1200mm centres. Horizontal and verticalchannel members either welded together or joined with steel angle cleats, minimum60mm x 60mm x 3mm thick x 60mm long, fastened to each channel member with twoM10 steel bolts and nuts.9.5mm Durasteel fillet fixed on both sides of channel. Fillet strips to overlap channel byminimum of 20mm on both sides.9.5mm Durasteel sheets fixed through fillet on both sides of the channel with M5.5 steelself 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.Length of fixing to be sufficient to ensure appropriate penetration of screw thread inaccordance with screw manufacturers recommendations.Vertical board joints coincide with studs, horizontal board joints are backed by steelchannel the same size as the vertical studs. Expansion allowance will be required forbarriers above 4 metres high.Steel Channel sizes for barrier heights up to 15 metresHeight of Channel size (mm x Durasteel fillets Rock Wool Estimated soundBarrier mm x mm) per face infill Insulation Row0-6 80 x 60 x 3 1 None 426-9 150 x 60 x 3 1 None 42 Two 150 x 60 x 39 - 12 1 None 42 Back to back Two 200 x 60 x 312 - 15 1 None 42 back to back
  24. 24. Back to back channels fastened together with M10 steel bolts and nuts at 500mmmaximum centres. The vertical joints in the Durasteel should be offset by 30mm fromthe centreline of the back-to-back studs, to avoid a straight through path for hot gases.Horizontal channels are single channels.Durasteel Fire Barrier E240 EI120Print This Page Email This Page Bookmark This Page • Fire resistance: 240 minutes integrity - 120 minutes insulation (Fire attack from either face) (Formally referred to as the STI 240/120 System) • Channel (minimum): 80mm x 60mm x 3mm (for heights up to 6m) • Overall width: 118mm • Weight (nominal): 62kg/m2 • Estimated sound reduction: 47dBPerimeter channels fastened to surrounding construction with M10 or M12 all-steelexpanding anchors (or equivalent for alternative types of supporting construction) at500mm maximum centres.The vertical channels are set at a maximum 1200mm centres. Horizontal and verticalchannel members either welded together or joined with steel angle cleats, minimum60mm x 60mm x 3mm thick x 60mm long, fastened to each channel member with twoM10 steel bolts and nuts.9.5mm Durasteel fillet strips fixed on both sides of channel, number of fillet stripsaccording to requirements in Table below. Fillet strips to overlap channel by minimumof 20mm on both sides. 9.5mm Durasteel sheets fixed through the fillet on both sides ofchannel, with M5.5 steel self drill and tap Tek screws at 250mm nominal centres. Fixingsa minimum of 12mm from edge of sheet and a maximum of 50mm from corners. Thelength of fixing to be sufficient to ensure appropriate penetration of screw thread, inaccordance with manufacturers recommendations. Vertical board joints coincide withstuds, horizontal board joints are backed by steel channel the same size as the verticalstuds. Rock wool infill, according to the table below, is fitted into the channels. Thelayers are staggered by a minimum of 150mm.
  25. 25. If the rock wool does not fill the cavity, it must be fastened into position with 2.5mm-diameter steel stud-welded pins and 38mm-diameter spring steel washers. The pins arepositioned in a grid 400mm x 400mm maximum. Expansion allowance will be requiredfor barriers above 4 metres high.Steel Channel sizes for barrier heights up to 15 metresHeight of Channel size (mm x Durasteel fillets Estimated sound Rock Wool infillBarrier mm x mm) per face Insulation Row 2 x 40mm x0-6 80 x 60 x 3 1 47 140kg/m3 3 x 50mm x6-9 150 x 60 x 3 None 51 80kg/m3 Two 150 x 60 x 3 3 x 50mm x9 - 12 None 53 back to back 80kg/m3 Two 200 x 60 x 3 4 x 50mm x12 - 15 None 53 back to back 60kg/m3Back to back channels fastened together with M10 steel bolts and nuts at 500mmmaximum centres. The vertical joints in the Durasteel should be offset by 30mm fromthe centreline of the back-to-back studs, to avoid a straight through path for hot gases.Horizontal channels are single channels.Durasteel Fire Barrier EI240Print This Page Email This Page Bookmark This Page • Fire resistance: 240 minutes integrity - 240 minutes insulation (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) • Overall width: 137mm • Weight (nominal): 72kg/m2 • Estimated sound reduction: 50dBPerimeter channels fastened to surrounding construction with M10 or M12 all-steelexpanding anchors (or equivalent for alternative types of supporting construction) at500mm maximum centres.
  26. 26. The vertical channels are set at a maximum 1200mm centres. Horizontal and verticalchannel members either welded together or joined with steel angle cleats, minimum60mm x 60mm x 3mm thick x 60mm long, fastened to each channel member with twoM10 steel bolts and nuts.9.5mm Durasteel fillets fixed on both sides of channel, number of fillet strips accordingto requirements in Table below. Fillet strips to overlap channel by minimum of 20mm onboth sides.9.5mm Durasteel sheets fixed through the fillet on both sides of channel, using M5.5steel self drill and tap Tek screws at 250mm nominal centres. Fixings a minimum of12mm from edge of sheet and a maximum of 50mm from corners. The length of fixingto be sufficient to ensure appropriate penetration of screw thread, in accordance withmanufacturers recommendations. Vertical board joints coincide with studs, horizontalboard joints are backed by steel channel the same size as the vertical studs.Rockwool infill, according to the table below, is fitted into the channels. The layers arestaggered by a minimum of 150mm. If the rock wool does not fill the cavity, it must befastened into position with 2.5mm-diameter steel stud-welded pins and 38mm-diameter spring steel washers. The pins are positioned in a grid 400mm x 400mmmaximum. Expansion allowance will be required or barriers above 4 metres high.Steel Channel sizes for barrier heights up to 15 metresHeight of Channel size (mm x Durasteel fillets Estimated sound Rock Wool infillBarrier mm x mm) per face Insulation Row 3 x 40mm x0-6 80 x 60 x 3 2 50 140kg/m3 3 x 50mm x6-9 150 x 60 x 3 2 55 100kg/m3 Two 150 x 60 x 3 3 x 50mm x9 - 12 2 55 back to back 100kg/m3 Two 200 x 60 x 3 4 x 50mm x12 - 15 1 56 back to back 80kg/m3Back to back channels fastened together with M10 steel bolts and nuts at 500mmmaximum centres. The vertical joints in the Durasteel should be offset by 30mm fromthe centreline of the back-to-back studs, to avoid a straight through path for hot gases.Horizontal channels are single channels.Typical Connection DetailsPrint This Page Email This Page Bookmark This Page
  27. 27. Please note that the following Durasteel system connection details are examples only.Connection details for each system will differ according to the specific requirements ofthe system.Wall Interface 1. 150mm x 60mm x 3mm CRC Frame 2. M10 Expanding Bolts at 500mm Maximum Centres 3. 15mm Promatect 250 4. 9.5mm Durasteel Sheet 5. Tek Screws at 200mm Maximum Centres 6. Silicone to all Abutments
  28. 28. Sheet Join Interface 1. 150mm x 60mm x 3mm CRC Frame Back To Back 2. M10 x 25mm Bolts c/w Nut and Washer 3. 15mm Promatect 250 4. 9.5mm Durasteel Sheet 5. Tek Screws at 200mm Maximum CentresBuilding Steel Penetration Interface 1. 150mm x 60mm x 3mm CRC Frame 2. 9.5mm Durasteel Sheet 3. 9.5mm Durasteel Sheet (2nd layer) 4. Existing Steelwork with Minimum 12mm Sealant Around Steelwork 5. Tek Screws at 200mm Maximum Centres
  29. 29. 6. 15mm Promatect 250Pipe Penetration Interface 1. 150mm x 60mm x 3mm CRC Frame 2. 9.5mm Durasteel Sheet 3. 15mm Promatect 250 4. Tek Screws at 200mm Maximum Centres 5. Existing Pipe 6. Rockwool Insulation 7. Promaseal Fire Compound 8. 100mm x 50mm x 3mm Rolled Steel Angle
  30. 30. Cleating - Corner Interface Elevation View 1. 150mm x 60mm x 3mm CRC Frame 2. 9.5mm Durasteel Sheet 3. M10 x 25mm Hex HD Bolts or M10 x 20mm CSK HD Bolts c/w Nut and Washer 4. 120mm x 60mm x 3mm Angle Cleats 5. M10 x 20mm CSK HD Bolts c/w Nut and Washer
  31. 31. Cleating - Perimeter Interface Elevation View 1. 150mm x 60mm x 3mm CRC Frame 2. 9.5mm Durasteel Sheet 3. M10 x 25mm Hex HD Bolts or M10 x 20mm CSK HD Bolts c/w Nut and Washer 4. 2 No. 120mm x 60mm x 3mm Angle Cleats 5. M10 x 20mm CSK HD Bolts c/w Nut and WasherCleating - Section View 1. 9.5mm Durasteel Sheet
  32. 32. 2. M10 x 25mm Hex HD Bolts or M10 x 20mm CSK HD Bolts c/w Nut and Washer 3. 150mm x 60mm x 3mm CRC Frame 4. 2 No. 120mm x 60mm x 3mm Angle Cleats 5. M10 x 20mm CSK HD Bolts c/w Nut and WasherCleating - Internal Interface Elevation View 1. 150mm x 60mm x 3mm CRC Frame 2. 9.5mm Durasteel Sheet 3. 120mm x 60mm x 3mm Angle Cleat 4. M10 x 20mm CSK HD Bolts c/w Nut and Washer 5. M10 x 20mm CSK HD Bolts c/w Nut and Washer
  33. 33. Cleating - Internal Interface Section View 1. M10 x 20mm CSK HD Bolts c/w Nut and Washer 2. 150mm x 60mm x 3mm CRC Frame 3. 120mm x 60mm x 3mm Angle Cleat 4. M10 x 20mm CSK HD Bolts c/w Nut and Washer 5. 15mm Promatect 250 6. 9.5mm Durasteel Sheet
  34. 34. Suspended Movement Head Detail 1. Profile Cut and Seal to Purlins 2. Curved 150mm x 60mm x 3mm CRC Head Channel 3. 9.5mm Durasteel Sheet 4. Tek Screws at 200mm Maximum Centres 5. 15mm Promatect 250 6. 80mm x 60mm x 3mm CRC Frame Back To Back 7. Slotted Cleat for 80mm x 60mm x 3mm CRC Frame
  35. 35. Standard Movement Head Detail 1. Profile Cut and Seal to Purlins 2. Curved 200mm x 60mm x 3mm CRC Head Channel 3. 9.5mm Durasteel Sheet 4. Tek Screws at 200mm Maximum Centres 5. 15mm Promatect 250 6. 150mm x 60mm x 3mm CRC Frame Back To Back 7. Slotted Cleat for 150mm x 60mm x 3mm CRC Frame
  36. 36. Wall Fixing 1. Dwarf Wall 2. Existing Plasterboard Wall 3. Mastic 4. Mastic 5. 150mm x 60mm x 3mm CRC Frame Back To Back 6. M10 x 25mm Bolts c/w Nut and Washer 7. 15mm Promatect 250 8. 9.5mm Durasteel Sheet 9. Tek Screws at 200mm Maximum Centres
  37. 37. Roller Shutter Steelwork Fixing 1. 50mm x 50mm x 3mm Angle 2. 150mm x 60mm x 3mm CRC Frame Back To Back 3. M10 x 25mm Bolts c/w Nut and Washer 4. 15mm Promatect 250 5. 9.5mm Durasteel Sheet 6. Tek Screws at 200mm Maximum Centres 7. Welded Plate Between Flanges 8. Mastic

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