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

2. 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

3. Fire Containment – Compartmentalize

4. 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.

5. 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.

6. 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.

7. 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.

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

9. 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

10. Hose Stream Test - Exposed Side

11. 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 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.

12. 1 to 4 Hour Ratings

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

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

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

19. Floor-Ceiling Prior to Test

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

21. 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.

22. 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.

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

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

25. 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

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

27. 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

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

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

30. Repair Small Holes

31. Repair Large Holes

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

33. 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

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