ICC 86 SFRM Inspector cheat sheet

ICC 86 SFRM inspection references IBC Chapter 7 (fire-resistance-rated construction) and the approved fire-resistance directory listings for the specific SFRM product.

ASTM E119 is the fire-test-response standard for building construction and materials; SFRM fire-resistance ratings are established by E119 testing of the specific assembly.

ASTM E736 covers cohesion/adhesion of sprayed fire-resistive materials; ASTM E605 covers thickness and density; ASTM E759 covers deflection under load.

UL 263 is the fire test standard equivalent to ASTM E119; listings in the UL Fire Resistance Directory specify required SFRM thickness and density for each assembly.

The SFRM manufacturer's published application instructions (ICBO/ICC-ES evaluation report or UL listing) are the governing document for mixing, thickness, and curing.

IBC Section 704.13 and 1705 require special inspection of SFRM where the fire-resistance rating is required; the statement of special inspection defines scope.

ASTM C635 covers manufacture, performance, and testing of metal suspension systems for acoustical tile; not directly SFRM but referenced in ceiling assemblies.

NFPA 70 (NEC) and NFPA 72 may be referenced for penetration protection and firestopping coordination with SFRM.

Project specifications (Division 07 81 00) often invoke ASTM E736, E605, and manufacturer requirements in addition to code.

SFRM types include cementitious (gypsum/portland cement based), fibrous (mineral wool or slag wool with binder), and intumescent coatings; each has distinct density and application requirements.

Fire-resistance principle: SFRM insulates steel by endothermic reaction and low thermal conductivity, slowing the temperature rise of the steel to maintain structural capacity.

Steel temperature limit for structural capacity is typically 1000°F to 1300°F depending on the member and code; SFRM must keep steel below this for the required rating time.

Density ranges: cementitious SFRM often 15–25 pcf; fibrous SFRM often 10–20 pcf; low-density fibrous may be 8–12 pcf. Verify with manufacturer data.

SFRM must be compatible with primers and shop coatings; incompatible coatings can cause adhesion failure.

Asbestos-containing SFRM is prohibited in new construction; existing SFRM must be tested before disturbance.

Intumescent coatings are thin-film and rely on swelling when heated; they are not SFRM in the traditional sense but may be inspected under similar protocols.

SFRM must be applied to clean, primed steel; galvanized surfaces may require a compatible primer or surface preparation per manufacturer.

Steel substrate must be free of oil, grease, dirt, loose rust, and mill scale; SSPC-SP 2 (hand tool) or SP 3 (power tool) cleaning may be specified.

Primers must be compatible with SFRM; shop primers are often required to be tested for adhesion per ASTM E736.

Ambient temperature during application typically must be at least 40°F (4°C) and rising; substrate temperature must be above 40°F unless manufacturer allows otherwise.

Ventilation must be adequate to remove moisture and dust; humidity limits per manufacturer (often <80% RH).

Surfaces must be dry; moisture can cause blistering or delamination of SFRM.

Masking and protection of adjacent surfaces, penetrations, and equipment is required before spraying.

Welded areas, bolts, and edges require SFRM coverage; sharp edges may need extra thickness or reinforcement.

Environmental conditions during curing must be maintained; freezing temperatures can damage uncured SFRM.

SFRM is typically applied by spraying using a mixer/pump and compressed air; dry mix and water are combined at the nozzle or in a mixing chamber.

Application is done in multiple passes; each pass thickness is limited by manufacturer (often 1/2 inch to 1 inch) to prevent sagging or poor adhesion.

Nozzle distance and angle affect density and uniformity; maintain consistent distance (typically 12–24 inches) and perpendicular to surface.

For fibrous SFRM, air pressure and material feed rate must be adjusted to achieve specified density; test panels may be required.

Curing time between passes varies with product and environment; follow manufacturer's recoat window.

Equipment must be cleaned regularly to prevent hardened material from clogging lines and affecting spray pattern.

Installation around penetrations, hangers, and supports must maintain required thickness and continuity; blocking or reinforcement may be needed.

Final thickness is achieved by building up passes; over-spray on adjacent surfaces must be removed before curing.

Thickness is measured per ASTM E605 using a depth gauge or caliper; measurements are taken at random locations on each member.

Density is determined per ASTM E605 by sampling a known volume of cured SFRM, weighing it, and calculating pounds per cubic foot (pcf).

Sampling frequency: typically one thickness measurement per 100 square feet and one density sample per 1000 square feet or per project, per ASTM E605.

Thickness must meet or exceed the specified thickness from the fire-resistance directory; average thickness and minimum individual thickness are evaluated.

Density must be within the range specified by the manufacturer and the listing; low density can reduce fire resistance.

Measurements should be recorded with location, member identification, and date; photographs are recommended.

For fibrous SFRM, density is critical because it affects cohesion and fire performance; samples must be taken from representative areas.

Test methods: ASTM E605 covers thickness and density; ASTM E736 covers cohesion/adhesion; ASTM E759 covers deflection.

Adhesion testing per ASTM E736 measures the bond between SFRM and substrate; cohesion testing measures internal strength of the SFRM.

Test method: a core sample is cut, a loading fixture is attached, and a tensile load is applied; failure mode (adhesive vs cohesive) is recorded.

Minimum adhesion/cohesion values are typically specified by the manufacturer or listing; often 150–1000 psf depending on product.

Test frequency: typically one test per 1000 square feet or per project, and at least one per substrate type and primer.

Tests should be performed after SFRM has cured sufficiently; follow manufacturer's minimum cure time.

Failure at the substrate indicates adhesion failure; failure within the SFRM indicates cohesion failure. Both are evaluated against acceptance criteria.

Areas that fail must be repaired and retested; documentation of failures and repairs is required.

ASTM E736 also provides for bond strength testing of sprayed fire-resistive materials.

Daily inspection reports should include date, weather, temperature, humidity, substrate condition, product used, batch numbers, and application thickness.

Records must include location of measurements, test results, and any deviations from specifications.

Photographs of before, during, and after application are valuable evidence of compliance.

Test reports for thickness, density, and adhesion must be retained and submitted to the authority having jurisdiction (AHJ).

Non-conformance reports (NCRs) document defects, repairs, and corrective actions; they must be closed out with verification.

Final inspection report should summarize compliance with the approved fire-resistance design and manufacturer instructions.

Records should be maintained for the project duration and as required by code; typically for the life of the building.

Inspection reports must be signed and dated by the inspector and kept on file.

Common defects: insufficient thickness, low density, poor adhesion, cracks, delamination, voids, and incomplete coverage.

Repair procedure: remove defective material to sound SFRM or substrate, clean, apply compatible primer if required, and reapply SFRM to specified thickness.

Repairs must be tested and documented; retest adhesion and thickness in repaired areas.

Cracks wider than a hairline may indicate cohesion failure; investigate cause and repair per manufacturer.

Delamination is often caused by poor surface preparation, incompatible primer, or moisture; correct root cause before repair.

Voids around penetrations and edges must be filled to maintain fire-resistance continuity.

Corrective actions should include root cause analysis and preventive measures to avoid recurrence.

All repairs must be approved by the AHJ and documented in the inspection record.