Project overview
Promat has played an instrumental part in the fire protection of the latest unit of GLP’s warehouse and logistics facility, G-Park, Northampton - providing a tailored 240-minutes fire resistance solution for Unit 4, a132,000 sq. ft speculative warehouse/distribution unit.
Situated within the popular Moulton Park industrial estate just north of the town and within 10 miles of J15 of the M1, G-Park has exceptional transport links, access to national markets, a locally skilled workforce and is home to a wide range of regional and national companies.
At short notice, the latest and final unit within the park required a solution that provided 4-hour fire resistance for the steel frame construction. Sub-contractor FAA Installation Ltd traditionally uses intumescent paints in its projects, but as this method was unable to meet the 4-hour fire protection required for the steelwork structure it was decided that boarding would be a more suitable alternative.
Promat VERMICULUX®-S and TD Boards® were specified for the project by Encon, a leading Promat distributor, as they knew that these were two of a limited number of products on the market that could meet the project’s requirements.
Promat worked closely with Encon and FAA on the final specification to provide a solution that could not only achieve the 240-minute requirement, but could also overcome the design complexities of the project, including fixing to both the structural steel and cladding rails, which most traditional boards were unable to accommodate. The completed installation demonstrates how VERMICULUX®-S and TD Boards® can interface together to create robust fire protection for warehouse and industrial applications.
Design and specification
Industrial units, such as Unit 4, are typically steel frame constructions that are vulnerable during a fire as the steel can quickly lose its structural integrity and load bearing capacity. This means that the correct specification of a fire protection solution that could provide 4 hours of fire resistance and meet current building regulations was essential for the project.
Promat was asked by Encon to speak to sub-contractor FAA Installations Ltd, who needed an appropriate solution in just a couple of days, as they were already on site. After looking at the specification requirements, it was clear that a tailored solution comprising Promat’s VERMICULUX®-S and TD Boards® was the answer.
Promat VERMICULUX®-S has been designed specifically to provide superior fire protection for structural steelwork making it the ideal fire protection solution for warehouses, industrial units and logistics facilities. Depending on the dimensions of the steelwork being protected, the lightweight, non-combustible calcium silicate boards can deliver up to 240 minutes of fire resistance.
The standard steelwork details were straightforward to accommodate, however a bespoke solution was required for the cladding rails. Working closely with Encon and FAA, Promat helped to design a solution that included 3-sided steel encasement details as the basis for the design, together with an adapted design solution for where the beams on the roof level met with the steel columns.
Promat’s in-house expertise meant the company was able to provide detailed drawings and specification details for FAA to work to, based on primary testing to European Standards 13381-4, backed by Third Party Certification.
Installation
Both VERMICULUX®-S and TD Boards are frameless systems with Vermiculux-S having a screw edge fix detail & TD board being either fully glued or stud welded pin fixed and have a screw fix edge, making them quick and easy to install which was a significant factor for the project.
The main challenge however was the interface detail between the cladding rails encased in TD Board® and the steel columns encased in VERMICULUX®-S. Promat proposed recommendations on how FAA should go about installing the interface detail for the two systems in line with their own test data and guidance given by the Association of Fire Protection Specialists (ASFP).
Promat provided continued consultancy and visuals throughout the whole of the project including additional support from its Construction Support Manager who visited the site to look over and double-check the details and fixings.
Final results
G-Park Unit 4 presented a challenge for all parties as a standard fire protection solution was not possible for the facility. Promat was able to offer a solution that combined its VERMICULUX®-S and TD Board® to guarantee the required 4-hour fire resistance, something that many other manufacturers are unable to provide for such an application.
Promat and Encon have a long-standing relationship and with Promat’s continual innovation, testing and support, Encon was confident that it could offer a solution that would meet the specific demands of the project and to the tight schedule.
The complexity and high value of the project meant that all parties needed to work closely together. As an off-the-shelf product was not suitable for the building’s design, FAA and Encon needed a solution quickly to avoid on-site delays. Promat was able to draw on the expertise of its technical teams to offer a bespoke solution within three days of being contacted by Encon. This was supported by technical assistance, drawings and installation details that met all specification requirements.
Neville White, Business Development Director at Encon, said: “This was a challenging project for all involved due mainly to speed in which all the elements needed to be put together. The technical detailing needed sorting with Promat, the products were needed on site within a very short time frame and FAA needed to install while other elements of the building were still being erected, namely the frame and the flooring. Encon were happy to lead the support here being the ‘Distributor of Choice’ and helping all parties achieve the required outcome for the client.
