Appendix III GUIDE TO ICBO EVALUATION REPORTS FOR MONOKOTE TYPE MK-6/HY, MK-6s and RETRO-GUARD (REPORT NO.

4607) In order to help you better understand ICBO Report No. 4607, the following explanation is provided. This explanation is separated into three parts. Part one discusses columns, part two, floor systems and part three, roof systems. Please read Appendix II to learn more about W/D ratios and fireproofing before reading this section. NOTE: ULI Fire Resistance Designs are updated more frequently than ICBO Evaluation Reports. Consult with your Grace sales representative regarding the possibility of making submittals based on UL Designs rather than the Evaluation Report. COLUMNS Page 2 on the ICBO Evaluation Reports contain column protection requirements. For wide flange and other column shapes, use Table 1A in the ICBO reports. Use Table 1B in the ICBO reports for tube and pipe elements. Table I-A of ICBO Report No. 4607 is reproduced below. It specifies the thickness of Monokote Type MK-6 or Retro-Guard required to provide up to four hours of fire-resistive protection to structural steel wide flange columns. Table 1A specifies the thickness of MK-6 or RG (rounded to 1/8 increments) required to protect various size W-shaped structural steel columns based on W/D ratios. Table 1A. Wide flange steel columns: Minimum thickness (inches): Size W/D ratio 4 HR Min. W14 x 730 6.62 5/8 Min. W14 x 228 2.49-6.61 1-1/4 Min. W12 x 106 1.44-2.48 1-7/8 Min. W10 x 49 0.83-1.43 2-1/2 Min. W8 x 28 0.67-.082 2-3/4 Min. W6 x 16 0.57-0.66 3-3/8 Min. W6 x 9 0.33-0.56 3-1/8 3 HR 3/8 7/8 1-1/2 1-3/4 2 2-1/2 2-1/2 2 HR 3/8 5/8 1 1-1/8 1-3/8 1-3/4 2 1 HR 3/8 3/8 1/2 3/4 3/4 7/8 1-1/8

The size designation of the structural steel is less important in determining thickness. The key determinate in finding the appropriate thickness is the W/D ratio of the structural steel. Each structural column shape has its own W/D ratio. Once a W/D ratio is known, that ratio is the key factor to determine thickness. The lower the W/D ratio, the greater the thickness of MK-6 or RG because light steel requires heavy thickness. Likewise, the higher the W/D ratio, the less thickness of MK-6 or RG because heavy steel requires light thickness. W/D ratios are listed in the thickness table based on ranges. For example, 2 inches of MK-6 or RG provide sufficient threehour protection for all columns with a W/D ratio between 0.67 and 0.82. Use of Table 1A is valid for all structural column shapes with a W/D ratio of 0.33 or larger. No matter how large the W/D ratio, the minimum thickness of Monokote or Retro-Guard shall be 3/8 inches (UL permits a minimum thickness of 1/4 inches). Again, Tube and pipe column protection must be determined from Table 1B. EXAMPLES: USING TABLE I-A As an example: For column W10x49, a three-hour rating is provided if 1-3/4 inches of MK-6 or RG is applied. If you need three-hour protection for a W8x18, find the W/D ratio for a W8x18. According to the Monokote Estimating Guide and UBC Standard No. 7-6, the W/D ratio for W8x18 is 0.49. For a W/D ratio of 0.49, three-hour protection is 3 inches since 0.49 falls between 0.33 and 0.56 in Table 1A. More fireproofing is required for the W8x18 than the W10x49 since it is a smaller column. Last, you require three-hour protection for a member with a W/D ratio of 3.70 is 7/8 inch. Since a W12x305 is significantly larger in weight and size than a W10x49, less thickness is required to provide the same three-hour fire-rating. As an option to using the range of W/D ratios found in Table 1A, Uniform Building Code Standard No. 7-6 approves the use of mathematical formulas to determine fireproofing thicknesses. Footnote 2 to Table 1A in January, 1998 Appendix I, Page i

ICBO Report No. 4607 (MK-6) provides a mathematical formula to determine the exact thickness of Monokote Type MK-6 or Retro-Guard to protect W-, M-, and S-shaped columns for a one-to four-hour fire rating. For your information, the formula for column protection in Footnote 2 of Table 1A in ICBO Report No. 4607 (MK6) or is identical to the thickness formula in UL Design X-772. Footnote 2 reads: As an alternate to Table 1A, thickness of fireproofing may be determined on the basis of the following equation: h = R/[1.05(W/D) + 0.61] Where: R = Fire resistance (hours) h = Thickness of fireproofing ranging from 0.375 to 3.875 inches D = Heated perimeter of steel column (inches) W = Weight of steel column (lbs. per lineal foot) W/D ratio ranges from minimum 0.33 to maximum 6.62 Minimum thickness is 3/8.

Limitations:

If you know the W/D ratio of an individual column element (W/D) and the required fire resistance rating in hours , you can calculate the exact thickness of Monokote Type MK-6 or Retro-Guard (h) required to provide a one, two, three or four-hour fire rating. EXAMPLES: COLUMN FORMULA As an example: You need the thickness of Monokote Type MK-6 or Retro-Guard to provide a two-hour fire-rating for a W14x99 which has a W/D ratio of 1.16. By substituting the 2 hour fire-rating requirement (R) and the 1.16 W/D ratio into the formula, the formula reads: h = 2/[1.05 (1.16) + 0.61]. The solution to the equation gives you the exact amount of Monokote Type MK-6 or Retro-Guard to provide two-hour protection to the W14x99. The answer is h = 1.094 inches or 1-1/8 inches (rounded to nearest 1/8th inch). The use of the column formula to determine protection requirements for OTHER structural elements based on the W/D calculation methods provided is subject to review and approval of the authority having jurisdiction. No Fire Resistance Designs address the use of these members.

The meaning of W/D other in the thickness tables In the material thickness tables published in this Handbook, you will find thicknesses for W shape members and other members. What is an other member? An other member is any structural shape (angles, channels, tees, etc.) which requires fire protection. For example, in Appendix II, the calculated W/D ratio for an L6x6x1/2 angle is 0.817. To determine the thickness of MK-6 or RG to provide a two-hour rating for an L6x6x1/2 angle, you could use the column thickness table in the ICBO Report and find the thickness for W/D ratio of 0.82. Using Table I-A above, the thickness would be 1-3/8 inches.

To assist you, W. R. Grace & Co. has provided the most cost effective thickness requirements for all column members using the published W/D approved formula in Footnote 2 to Table 1A for wide flange members and Footnote 3 to Table 1B for tube and pipe members. The thickness tables for column members appear in this Handbook. For the specific location of column thickness tables, see the Table of Contents. Please note that for ICBO use, it will be necessary to round up to the nearest 1/8 inch increment.

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Appendix I, Page ii

FLOORS Before you can determine the amount of Monokote Type MK-6 or Retro-Guard to protect a floor support, you must first know what the type of floor assembly the beam, girder or joist supports. Beams, girders or joists support either a protected or unprotected deck. A protected deck is one which receives Monokote Type MK-6 or Retro-Guard on the underside of the deck. Unprotected decks do not require fireproofing on the underside of the deck. The type of concrete (normalweight or lightweight), its thickness and the span between supports determines whether or not the deck needs fireproofing. The table below will help you determine what floor decks require fireproofing and what floor decks do not require fireproofing. The table below is based on UL Design D-925 and the individual ICBO Evaluation Reports of metal deck manufacturers (For example, Verco Manufacturings ICBO Evaluation Report No. 2078 or ASC Pacifics ICBO Evaluation Report No 2757). Once you determine the type of concrete and its thickness above the top flute of the deck, you should be able to use the table below to determine whether the deck needs fireproofing. Does the Underside of the Floor Deck Require Fireproofing? Type and Thickness of Slab over Flutes 1 HR 2 HR 3 HR Normalweight Concrete (1503 pcf) Minimum 2 Yes Yes Yes Minimum 2-1/2 Yes Yes Yes Minimum 3-1/2 No * Yes Yes Minimum 4-1/2 No * No * Yes Minimum 5-1/4 No * No * No * Lightweight Concrete (1103 pcf) Minimum 2 Yes Yes Yes Minimum 2-1/2 No * Yes Yes Minimum 3-1/4 No * No * Yes Minimum 4-3/16 No * No * No * * Check span limitations in D-925 4 HR Yes Yes Yes Yes Yes Yes Yes Yes Yes

Notes: Ratings may not be applicable where rigid roof insulation is placed above the slab or batt insulation is placed below the slab. Ratings for lightweight concrete apply only to 110 pcf3 density. Confirm density. For other lightweight density ranges, see UL Design D925 Spatterkote is required on all flat plate cellular decking. Check with the structural engineer regarding use of restrained assembly ratings. If you determine that the floor deck requires fireproofing, use the guide below to find the appropriate thickness to protect the underside of the floor deck in ICBO Report No. 4607 (MK-6). The table below does not address electrified floor systems. Consult Appendix III for more information regarding fireproofing electrified floor systems using trench headers and preset inserts. If the Deck Sprays (Protected): Slab 2-1/2 over flutes or thicker Slab 2 over flutes Use Floor Deck Table No. Table 2-A-2 Table 2-B-2 Page No. 3 4

After you determine the floor deck fireproofing requirements, use the guide below to find the appropriate floor beam or joist thickness requirements in ICBO Report No. 4607 (MK-6). If the Deck Sprays (Protected): 2-1/2 or thicker Normalweight 2-1/2: or thicker Lightweight 2 Normalweight 2 Lightweight If the Deck does not Spray (Unprotected): Use Floor Beam/Joist Table No. Table 2-A-3a or -3b Table 2-A-4a or -4b Table 2-B-3 Table 2-B-4 Table 3-A-2 or -3 Page No. 3 3 5 5 6

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As an example, let us assume the floor construction is 2-1/2 normalweight slab above the top of the flutes of the deck which means that the beam support thicknesses can be taken from Table 2-A-3a in ICBO Report No. 4607. Table 2-A-3a of ICBO Report No. 4607 (MK-6) specifies the thickness of MK-6 or RG required to provide up to four-hours of fire-resistive protection to structural steel beams or girders supporting a protected floor deck with at least 2-1/2 normalweight slab. The table below is reproduced from Page 3 of ICBO Report No. 4607 (MK-6). This table specifies the thickness of Monokote or Retro-Guard (rounded to 1/8 increments) required to protect various sizes of structural steel floor supports based on W/D ratios. Table 2-B-3a. Floor beams supporting a normal-weight concrete slab: Min. unrestrained fireproofing thicknesses (inches). Beam Size W/D ratio 4 HR 3 HR 2 HR 1 HR Min. W8x67 1.60 or larger 1-3/8 7/8 5/8 3/8 Min. W10x60 1.20 - 1.59 1-5/8 1 3/4 1/2 Min. W8x28 0.80 - 1.19 2 1-1/4 7/8 1/2 Min. W8x10 0.37 - 0.79 2-7/8 1-7/8 1-3/8 3/4 Joists With or without lath, scrim or net 2-7/8 2-3/4 2-1/4 1-1/8 The size designation of the structural steel is less important in determining thickness. The key determinate in finding the appropriate thickness is the W/D ratio of the structural steel. For each structural floor beam shape, a W/D ratio can be calculated. Use of Table 2-A, item 3a is valid for all structural floor beam shapes with a W/D ratio of 0.37 or larger. No matter how high the W/D ratio, the minimum thickness of Monokote Type MK-6 or Retro-Guard shall be at least 3/8 inches. Since floor beams are typically exposed to fire on three sides and columns are exposed to fire on four sides, the W/D ratio for the same structural shape will differ based on whether it functions as a beam or column. For example, the W/D ratio for a W6x16 is 0.57 if it functions as a column and 0.66 if it functions as a beam. W/D ratios do not apply for open web floor joist supports. When approved in the floor assembly, the thickness requirement for joist supports are published in the same table with beams. Minimum size joist elements permitted in floor assemblies are reported in Footnotes to the thickness tables. Also note that the bridging which is part of the joist construction is also required to be protected. EXAMPLES: USING TABLE II-A-3a As an example: You need three-hour protection for a W8x28. You look up the W/D ratio for a W8x28 and find it is 0.80. Using Table 2-A-3a, three-hour protection for a floor beam with a W/D ratio of 0.80 is 1-1/4 inches. You now need three-hour protection for a W8x18. The W/D ratio for a W8x18 is 0.57. For a W/D ratio of 0.57, three-hour protection is 1-7/8 inches. More fireproofing is required for the W8x18 than the W8x28 since it is a smaller sized floor beam. Last, you need three-hour protection for a W14x120 which has a W/D ratio of 1.67. According to Table II-A-3a, three-hour protection for a member with a W/D ratio of 1.67 is 7/8 inch. Since a W14x120 is significantly larger in weight and size than either a W8x18 or W8x28, less thickness is required to provide the same three-hour rating. As an option to using the floor beam thicknesses in Table 2 or Table 3 which are based on a range of W/D ratios, UBC Standard No. 7-6 permits the use of mathematical formulas to determine the exact fireproofing thickness for floor supports. For example, Footnote 2 to Table 2-A-3a provides a mathematical formula to determine the exact thickness of Monokote Type MK-6 or Retro-Guard to protect floor beams for a one to fourhour fire-rating. The formula for floor beam protection in Footnote 2 of Table 2-A-3a is identical to the Adjustment of Sprayed Protection Material Thickness For Unrestrained Beam Ratings For Various Sizes formula published in the introduction to the UL Fire Resistance Directory. Footnote 2, reproduced from page 5 of ICBO Report No. 4607 (MK-6) reads: As an alternate to Table 2-A-3 or -4, thickness for unrestrained beams may be determined by the following equation:

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Appendix I, Page iv

T1 = [(W2/D2) + 0.6]T2 / [(W1/D1) + .6] Where: Thickness of Fireproofing (inches) Weight of steel beam (lbs. per lineal foot) Heated perimeter of steel beam (inches) Refers to desired beam size and required material thickness 2 = Refers to given floor beam size and material thickness which is W8x28 (W/D ratio 0.80) Minimum thickness shall not be less than 3/8 inch W/D Ratio shall no be less than 0.37 T W D 1 = = = =

Limitations:

By substituting the W/D ratio of the given floor beam (W2/D2) and its required thickness (T2) and the W/D ratio of the desired floor beam (W1/D1), you can calculate the exact thickness of Monokote Type MK-6 or Retro-Guard (T1) required to provide a one, two, three or four-hour fire rating. EXAMPLES: FLOOR BEAM FORMULA As an example: You need the thickness of Monokote Type MK-6 or Retro-Guard to provide a two-hour fire-rating for a W14x68 which has a W/D ratio of 1.19 and supports a 2-1/2 normalweight concrete slab. Because W14x68 is the desired floor beam, W1/D1 is 1.19. Since the given floor beam (W2/D2) is a W8x28 which has a W/D ratio of 0.80 and the given two-hour thickness (T2) for the W8x28 is 7/8 (full flange), the formula reads: T1 = [(0.80 + 0.6)7/8/[(1.19 + 0.6)]. The solution to the equation gives you the exact amount of MK-6 or Retro-Guard to provide twohour protection for floor beam W14x68. The answer is T1 = 0.684 inches. For a floor beam W8x10 which has a W/D ratio of 0.37, the formula reads: T1 = .[(0.80 + 0.6)7/8/[0.37 + 0.6)] and the answer is T1 = 1.262 inches. To assist you, W. R. Grace & Co. has calculated the thickness requirements for all floor beam members using the approved formula in Footnote 2 to Table 2 and Footnote 3 to Table 3 for wide flange and other members. The thickness tables for floor beam members appear in this Handbook. For the specific location of floor beam thickness tables, see the Table of Contents.

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ROOFS Before you can determine the amount of Monokote Type MK-6 or Retro-Guard to protect a roof support, you must first know what the roof beam or girder supports. Beams or girders support either a protected or unprotected roof deck. A protected deck is a deck which receives Monokote or Retro-Guard on the underside of the deck, such as rigid roof insulation attached over metal deck. Unprotected roof decks do not require fireproofing on the underside of the deck. The type and thickness of roof insulation determines whether or not the underside of the roof deck needs fireproofing. (See the Table of Contents.) ICBO Report No. 4607 (MK-6) includes five rigid roof insulations which require Monokote Type MK-6 or Retro-Guard protection to the underside of the roof deck. It is important to know what rigid roof insulation is specified. If more than one rigid roof insulation is specified, you may have to qualify your bid or be prepared to bid separate prices for each type of roof insulation used. If a roof insulation is specified that is not listed in the ICBO Report, contact the architect for clarification. Once the type of insulation is known, you can determine the amount of fireproofing required beneath the roof deck (if any) and the amount of fireproofing required on the roof supports. by finding the appropriate table for that roof insulation in the ICBO Evaluation Report. The guide below lists the various types of roof insulation found in ICBO Report No. 4607 . Roof Insulation Mineral or Fiber Polystyrene Foam Fiberglass Polyurethane Foam Polyisocyanurate Foam Extruded Polystyrene (IRMA) Insulating Concrete Roof Fireproof? Yes Yes Yes Yes Yes Yes No Deck Spatterkote SK-III Needed? Optional Optional Optional Required Required Optional No What Table in ICBO? 6-A 6-B 6-C 6-D 6-E 6-F 7-A

A Word on Spatterkote Spatterkote is a mill-mixed cementitious material that must be applied as a bond promoter to some roof decks prior to the application of Monokote or Retro-Guard. The use of Spatterkote is optional and recommended inn all other roof-ceiling designs. Spatterkote is manufactured by W. R. Grace & Co.-Conn. A word on Gypsum wallboard. Some roof constructions may require gypsum wallboard above the metal deck. Other roof construction offers a reduction in fireproofing thickness if gypsum board is used. In either case, make sure your bid section does not include installation of gypsum board, unless of course you desire to install it. As an example, let us assume the roof construction is a mineral fiber roof insulation above the deck which means that the deck and beams must be fireproofed. The deck and beam/joist thicknesses can be taken from Table VIA-4 in ICBO Report No. 4607 which is reproduced below. Table 6-A-4 of ICBO Report No. 4607 specifies the thickness of Monokote or Retro-Guard required to protect the underside of the roof deck and the roof beams based on W/D ratios. The table below was taken from Page 8 of ICBO Report No. 4607. Table 6-A-5. Fireproofing thicknesses (inches) 3 HR 2 HR 1 HR Deck: NR 2-1/4 1-1/4 Beam: Min. W6x16 W/D ratio 0.66 or larger 1-1/2 1-1/8 3/4 Min. W8x10 W/D ratio 0.37-0.65 2 1-1/2 1 Joist: 14J7 With or without scrim, lath or net NR 1-7/8 1-1/2 12J4 With scrim, lath or net NR 1-7/8 1-3/4 12J4 Without scrim, lath or net NR 2-1/2 2-1/4 Bridging 5 : L1-5/8x1-5/8x1/4 NR 1-7/8 1-7/8

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Just as with floor beams, fireproofing roof beams is based on W/D ratios. The Size designation of the structural steel is less important in determining thickness. The key determinate in finding the appropriate thickness is the W/D ratio of the structural steel. For each structural roof beam shape, a W/D ratio can be calculated. Use of Table 6-A-5 is valid for all structural roof beam shapes with a W/D ratio of 0.37 or larger. No matter how high the W/D ratio, the minimum thickness of Monokote Type MK-6 or Retro-Guard shall be at least 3/8 inches. Table 6-A-5 also includes thickness requirements for joist supports (based on depth and size) and bridging. In some occupancy types, building code provisions allow the elimination of fireproofing from the underside of a roof otherwise requiring protection based on roof heights. If the structural members still require protection, protection must be selected using an applicable ULI S-700 series design.

EXAMPLES: USING TABLE VI-A-4 As an example: You need two-hour protection to a roof deck construction using mineral fiber insulation. According to Table 6-A-5, 2-1/4 inches of MK-6 or RetroGuard will provide the fire-rating. For the roof beams, you need two-hour protection for a W6x16. You look up the W/D ratio for a W6x16 and find it is 0.66. Using Table 6-A-5, two-hour protection for a roof beam with a W/D ratio of 0.66 is 1-1/8 inches. You now need two-hour protection for a W8x18. The W/D ratio for a W8x18 is 0.57. For a W/D ratio of 0.57, two-hour protection is 1-1/2 inches. More fireproofing is required for the W8x18 than the W8x28 since it is a smaller sized roof beam. As an option to using the roof beam thickness in Table 6 or Table 7 which are based on a range of W/D ratios, UBC Standard No. 7-6 permits the use of mathematical formulas to determine the exact fireproofing thickness for roof beams. For example, Footnote 3 to Table 6 provides a mathematical formula to determine the exact thickness of Monokote Type MK-6 or Retro-Guard to protect roof beams for a one to three-hour fire rating. The formula for roof beam protection in Footnote 3 to Table 6 is identical to the Adjustment of Sprayed Protection Material Thickness For Unrestrained Beam Ratings For Various Sizes formula published in the introduction to the UL Fire Resistance Directory. Footnote 3, reproduced from page 10 of ICBO Report No. 4607 (MK-6) reads: As an alternate to the roof beams thicknesses provided in the Table, thicknesses for unrestrained beams may be determined by the following equation: T1 = [(W2/D2) + 0.6]T2 /[(W1/D1) + .6] Where: Thickness of Fireproofing (inches) Weight of steel beam (lbs. per lineal foot) Heated perimeter of steel beam (inches) Refers to desired beam size and required material thickness 2 = Refers to given floor beam size and material thickness which is W6x16 (W/D ratio 0.66) Minimum thickness shall not be less than 3/8 inch W/D Ratio shall no be less than 0.37 T W D 1 = = = =

Limitations:

By substituting the W/D ratio of the given roof beam (W2/D2) and its required thickness (T2) and the W/D ratio of the desired roof beam (W1/D1), you can calculate the exact thickness of Monokote or Retro-Guard (T1) required to provide a one, two or three hour fire-rating.

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EXAMPLES: ROOF BEAM FORMULA As an example: You need the thickness of Monokote Type MK-6 or Retro-Guard to provide a two-hour fire rating for a W14x68 which has a W/D ratio of 1.19 and supports a roof deck with polyisocyanurate roof insulation (Table 6-E). Because W14x68 is the desired roof beam, W1/D1 is 1.19. Since the given roof beam (W2/D2) is a W6x66 which has a W/D ratio of 0.66 and the given two-hour thickness (T2) for the W6x66 is 1-1/8, the formula reads: T1 = [(0.66 + 0.6)1-1/8/[1.19 + 0.6)]. The solution to the equation gives you the exact amount of Monokote Type MK-6 or Retro-Guard to provide two-hour protection for roof beam W14x68. The answer is T1 = [(0.66 + 0.6)1-1/8:/[0.37 + 0.6)] and the answer is T1 = 1.461 inches.

To assist you, W. R. Grace & Co. has calculated the thickness requirements for all roof beam members using the approved formula in Footnote 3 to Table 6 and Footnote 5 to Table 7 for wide flange and other members. The thickness tables for roof beam members appear in this Handbook. For the specific location of roof beam thickness tables, see the Table of Contents.

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Appendix I, Page viii