Barrier Management Symposium Nov. 16, 2015 Bill McHugh, FCIA for Nestor Sanchez, USG Corporation

Learning Objectives Explore the gypsum mineral and its impact on fire resistance in a systems basis Understand the different types of gypsum core and their relation to fire resistance Determine recognized methods for repair installed gypsum panels Innovative Technology

Fire Containment – Compartmentalize

Gypsum Mineral Calcium Sulfate CaSO4.2H2O 20% water by weight Gypsum is a natural mineral and is found abundantly in nature. The chemical composition of gypsum is Calcium Sulfate and 2 molecules of water. This means that 20% of our product is water. It is this chemically combined water that is the root of the mineral’s fire resistivity.

Gypsum Mineral ASTM E 119 2hr. 1900o F The next few slides will illustrate this. Let’s pretend that we have a six inch thick piece of gypsum that is exposed to a fire test. One of the parameters of the ASTM fire test procedure that determines fire rating is the temperature on the exposed side of the sample as a function of time. After two hours exposure, the exposed side of our six inch thick gypsum will be 1900o Fahrenheit.

Gypsum Mineral 1” back 950o F One inch back, the temperature has dropped to 950o! That’s almost one thousand degrees in one inch! The reason for this is that water below its boiling point tends to stay below the boiling point until all of it is transformed into steam. If we take a paper cup of water and place directly in a flame the cup will not burn away until the water boils away.

Gypsum Mineral 2” back 220o F Two inches back we come to the solid line I’ve drawn. Here the temperature has dropped to the boiling temperature of water (220oF). All the gypsum to your left has been fully calcined, while all the gypsum to the right is still in its natural form.

Gypsum Mineral 4” back 180o F Four inches back, the temperature has dropped to 180oF, and finally at six inches........

Gypsum Mineral 6” back 130o F the temperature is down to 130o F. This means that in six small inches the temperature went from 1900oF down to a mere 130oF. The only thing that allows that to happen is the calcination of the gypsum mineral

Hose Stream Test - Exposed Side

Cold-Formed Steel Background The primary raw materials that comprise steel are iron ore, Carburized coal or coke, and recycled steel. Iron ore is a naturally occurring metallic oxide. An oxide that makes up about 5% of the earth’s crust. Carburized coal or coke is coal with a high carbon content. Coke is a naturally occurring material, and the World Steel Association estimates that there are at least 100 years supply. Coke can be man made from regular coal. The construction industry boasts a 85% recycle rate for steel. The Steel Recycling Institute reports that in 2008 475 million tons of steel scrap was removed from the waste stream. Steel is recycled more than paper, plastic, glass, copper, lead, and aluminum – COMBINED! From a sustainability standpoint, the EPA states that the U.S. Steel industry has reduced what are called greenhouse gas emissions by 47%. Also, the World Steel Association claims that since 1975 the world wide steel industry has lowered energy consumption by 50%. Sheet steel is protected by a protective coating, and then shipped from the mill in coils. The industry standard for corrosion resistance is galvanization, which means coating the steel in zinc. The upper picture here are galvanized coils of steel that are ready to leave the steel mill. At the steel fabricators, lets say steel stud manufacturer, the coils have to be slit into blank widths. Each profile has a blank width associated to its shape. The coils of blank width are then fed through a series of dies (shown in the center picture) in a continuous process where the dies gently bend the steel into its final shape. The picture at the bottom depicts the many profiles that are used in the construction industry. They include studs, tracks, furring channels, Z-channels, and various accessories. CFS Shapes used in construction come in a wide range of thicknesses. The studs are manufactured to be either structural or non-structural. The framing members are available in many depths and thicknesses. The thicknesses start at 18 Mils = 25ga, and include 33 Mils (20 Ga,), 43 Mils (18 Ga.), 54 Mils (16 Ga.), 68 Mils (14 Ga.) and finally 97 Mils = 12 ga. This wide range of depths and thicknesses allows for optimization of design to meet specific design requirements. The most common sections are: S = C Studs and Joists T = Tracks U = Channels F = Furring Channel In the past we called out the thickness of steel in Gauges. Now the industry has moved to Mils. A Mil is the Uncoated material thickness expressed on 1/1000’s inches.

1 to 4 Hour Ratings

Three (3) Types of Gypsum Cores Gypsum Core Types Three (3) Types of Gypsum Cores Regular Core Type X Type C

Panel Strength Comparison Simple Test @ 1850o F 13” x 13” x 5/8” Panels Regular, Type X & Type C Panels 12lb - 9oz. loading

Significance of Test Type X core  Type C core Specify board type per UL design Specified panel must be installed

Floor-Ceiling Prior to Test

GA-605 – Gyp. Panel Products for use in UL Classified Systems Free to download www.gypsum.org Gyp. Mfg. UL Type & Product Name www.UL.com Fire Resistance Directory

GA-605 Type “C”: Ex. Mfg. Name & UL Type American Gypsum: AG-C CertainTeed: ProRoc Type C GP: Type 5 LaFarge: Type LGFC-C/A National Gypsum: Type FSW-C Pabco: Type PG-C & Type C Temple-Inland: Fire Rated Type TG-C USG: Type C * not all mfg.’s “C” core panels listed. See mfg.

GA-605 Type “X” : Ex. Mfg. Name & UL Type American Gypsum: Type AGX-1, AGX-11 CertainTeed: ProRoc Type X GP: Type 9 LaFarge: Type LGFC6A National Gypsum: Type FSW Pabco: Type PG-11 Temple-Inland: Fire Rated Type X USG: Type SCX * not all mfg.’s “X” core panels listed. See mfg.

Orientation of Gypsum Panels on Walls Perpendicular to the studs (horizontally applied) Parallel to the studs (vertically applied)

Orientation of Gypsum Panels on Walls Conventional studs (minimum 25 gauge) Light gauge studs (equivalent thickness)

Orientation of Gypsum Panels on Walls On Conventional Studs Vertical application – Standard Horizontal application – Referenced in the IBC and GA 600 – Based on an old test Achieved by most wallboard manufacturers at UL

Orientation of Gypsum Panels On Light Gauge Studs Vertical application – Standard - Most manufacturers Horizontal application – Only achieved at UL with certain manufacturers

Fire Performance Light Gauge Steel Stud Construction – UL U419 Perpendicular (horizontal) installation with aligned horizontal joints Top-down construction 1-hr Rated System Horizontal Without Backing

VERTICALLY 1 HOUR GYPSUM BOARD APPLIED WALL JOINTS IN FINISH LAYERS TO RECEIVE PERF-A-TAPE AND JOINT COMPOUND STUDS 16” O.C.

Repair Gypsum Panels Incidental Tears Small Indentation Fractured Core “Crease in Panel” Back Paper Damage

Repair Small Holes

Repair Large Holes

Innovations Mold – Resistant Boards Lightweight Gypsum Panels Regular Core Lightweight Gypsum Panels Dust Control Joint Compound

Resources U.L. Fire Resistance Directory Gypsum Association Manufacturers’ Catalogs Technical Websites UL Ultimate Fire Wizard GA Association – gypsum.org Steel Framing Alliance – steelframing.org

Barrier Management Symposium Nov. 16, 2015 Bill McHugh, FCIA for Nestor Sanchez, USG Corporation