Fire Rated Pipe Insulation, Wraps & Collars: UK Guide to Standards & Safety

Section 7: Ablative Coatings in Firestopping

Ablative coatings are a crucial component in passive fire protection, often used to enhance the fire resistance of various systems, including penetration seals for pipes and ducts. These are typically water-based acrylic coatings that can be applied by brush or spray.

The primary fire protection mechanism of an ablative coating involves a process of controlled erosion or consumption when exposed to fire. When heated, these coatings undergo a chemical reaction that often releases water vapour. This release of vapour has a cooling effect on the surface it protects and on the fire-rated application beneath it.

As the coating ablates (erodes), it forms a char or an insulating barrier that helps to slow down heat transfer and prevent the spread of fire and smoke. At standard temperatures, many ablative coatings remain flexible, allowing for thermal and mechanical movement of services, but during a fire, they form a resilient barrier.

Ablative coatings are commonly used to coat fire batts (high-density mineral wool boards) on one or both sides. This coating significantly enhances the fire batt's performance by sealing the porous surface of the mineral wool, preventing the passage of smoke and hot gases, and improving its integrity and insulation characteristics during a fire. The coating also provides a more durable and damage-resistant surface to the batt.

Beyond coating fire batts, ablative liquids are also used to:

• Seal joints and edges: When fire batts are cut and fitted around services or into openings, ablative coating (or a compatible ablative mastic) is applied to all cut edges and joints between batt sections, and between the batt and the surrounding structure, to ensure a complete fire and smoke seal.
• Reinstate damaged coatings: If the ablative coating on a fire batt is damaged during installation or subsequent works, liquid ablative coating can be applied on-site to repair the damage and maintain the system's integrity.
• Back-coat services or substrates: In some tested systems, ablative coatings may be applied directly to certain services or the surrounding substrate as part of a comprehensive firestopping detail. However, this is less common for direct pipe firestopping compared to their use with batts. Their primary role in pipe and duct penetrations is typically as part of a fire batt system.

Manufacturers like Rockwool, Astroflame, PFC Corofil, FSi, Nullifire, and Quelfire offer ablative coating products. These coatings are tested as part of penetration sealing systems to standards such as BS EN 1366-3. The assumed working life of these coatings can be significant, often cited as 25 years or more when applied correctly.

Section 8: Fire Batts for Complex Penetrations and Large Openings 

Fire batts, also known as fire-rated boards or mineral wool boards, are a critical component in passive fire protection. They are particularly useful for sealing larger or more complex service penetrations and voids in fire-rated compartment walls and floors.

They typically consist of a high-density stone wool (mineral wool) core and are often pre-coated on one or both sides with an ablative coating. This ablative coating enhances the fire batt's performance by providing a smoke and gas seal, improving fire resistance, and offering a more durable surface.

How Fire Batts Work in Penetration Sealing

Fire batts are used to reinstate the fire resistance of a compartment wall or floor where larger openings have been created for multiple services (pipes, cables, ducts) or for single large services. Their function is to:

• Fill the void: The batt is cut to size and friction-fitted into the aperture, creating a physical barrier.
• Provide insulation and integrity: The dense mineral wool core offers inherent fire resistance, slowing heat transfer, while the ablative coating helps maintain integrity against flames and hot gases.
• Support other firestopping products: Fire batts often form the substrate or supporting structure for other firestopping components like pipe collars, intumescent wraps, or sleeves when dealing with service penetrations passing through the batt.

Using Fire Batts with Pipe and Duct Penetrations

When pipes (plastic or metal) or ducts penetrate an opening sealed with a fire batt system, the following general principles apply:

• Creating the Opening in the Batt: An aperture is carefully cut into the fire batt to accommodate the penetrating service. This cut should be as neat and tight to the service as possible.
• Installing the Service Firestop:
  • Pipe Collars: Fire collars can be fixed directly to the surface of the ablative-coated fire batt. For example, Rockwool details show their FirePro Pipe Collar CE being secured through Ablative Coated Batt using steel pigtail screws. Similarly, FSi's PipeBloc PCP collars can be installed onto their Stopseal Batt System. The collar then functions as described previously, crushing plastic pipes or sealing around insulated metal pipes upon heat exposure.
  • Pipe Wraps: Intumescent pipe wraps, including those designed as a fire rated pipe wrap for specific durations like 2 hours, can be installed within an aperture in a fire batt system. The wrap is fitted around the plastic pipe or the combustible insulation on a metal pipe. The surrounding batt (often with an intumescent sealant applied around the wrap within the batt) provides the necessary containment for the wrap to crush the plastic pipe or fill the void around the metal pipe effectively. Protecta FR Pipe Wraps, for instance, can be fitted within their FR Board system.
  • Fire Sleeves (for pipes and ducts): Insulated fire sleeves (often mineral wool based, sometimes with intumescent components) or duct sleeves are installed around the pipe or duct where it passes through the fire batt. These sleeves often need to protrude a specific distance from the face of the batt, as per the manufacturer's tested details. For example, Rockwool Insulated Fire Sleeves, when used with Ablative Coated Batts, are required to extend beyond the face of the batt. A minimum width of batt material must be maintained between sleeves and the edge of the aperture or other sleeves. Quelfire QRS Duct Sleeves are also suitable for installation within their QuelStop Fire Batt system. For uninsulated metal pipes passing through a fire batt, specific lagging with mineral wool pipe sections (e.g., Rockwool Fire Tube or Pipe Section) for a defined length through and extending from the batt may be required to achieve the necessary insulation (I) rating.
• Sealing: All joints between batt sections, between the batt and the surrounding structure, and around the services or firestopping devices within the batt must be sealed with a compatible fire-rated sealant (typically an intumescent or ablative mastic) to ensure a complete smoke and fire seal. Cut edges of the batt itself are also typically coated with ablative sealant or coating.

Installation Considerations for Fire Batts:

• Friction Fit vs. Pattress Fit: Batts can be friction-fitted tightly into an opening or pattress-fitted, where the batt is larger than the opening and fixed to the face of the wall/floor, overlapping the aperture.
• Support for Services: Services passing through fire batts must be independently supported on both sides of the seal, ensuring no load is transferred onto the firestopping system. The first support is typically required within a specific distance from the face of the seal (e.g., 400mm).
• Multiple Services: When multiple services penetrate a fire batt, minimum spacing requirements between services and between services and the edge of the batt must be adhered to, based on tested configurations.

Fire batts are available from various manufacturers, including FSi (Stopseal), Astroflame, Nullifire (FB750 Intubat), Rockwool (Ablative Coated Batt), Quelfire (QuelStop), and Protecta (FR Board). These systems are tested to standards like EN 1366-3 and can provide fire resistance for up to 240 minutes (EI240), depending on the specific product, thickness, and application.

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Section 9: Spotlight on Specific Manufacturer Solutions for Pipe and Duct Firestopping

Several specialised manufacturers offer a wide array of tested and certified firestopping products for pipes and ducts. Understanding the offerings from some of these key players can aid in selecting appropriate solutions.

A. Astroflame Firestopping Products

Astroflame provides a comprehensive range of passive fire protection items, including solutions for pipe and duct penetrations.

• Pipe Collars:
  • Astroflame X Series CE Intumescent Pipe Collars / PFP Pipe Closers: These collars are primarily designed to reinstate the fire resistance of compartment walls and floors penetrated by combustible plastic pipes (PP, PE, PVC-U, ABS, SAN+PVC). They feature a mild steel case containing a graphite intumescent material that expands in heat to crush the melting pipe and seal the opening. These collars are CE Marked, Certifire Approved, and tested to EN 1366-3, offering fire resistance up to 240 minutes. They are available for pipe diameters from 32mm to 315mm, and some designs feature a reduced height for installations in tight spaces. The intumescent material typically begins to expand around 105°C. While primarily for plastic pipes, always check specific test data if considering for insulated metal pipes.
• Pipe Wraps:
  • Astro PFP FR Pipe Wraps / X Series PFP Pipe Wraps: These consist of a graphite-based reactive intumescent strip, a type of fire rated pipe wrap. They are designed to be wrapped around plastic pipes (PVC-U, PVC-C, PE, LDPE, MDPE, HDPE, ABS, SAN+PVC, PP), conduits, or metal pipes (copper, steel) with continuous combustible insulation. When heated (minimum expansion temperature 150°C), the intumescent expands (approx. 28:1 ratio) to close the void left by the melting plastic or insulation around the metal pipe. They can provide fire classifications up to 240 minutes (e.g., a 2 hour fire rated pipe wrap performance or higher is achievable depending on the specific product and application) for integrity and insulation and are tested for U/U pipe end applications. These intumescent wraps are installed by securing them around the pipe with a self-adhesive tab. The annular space is then sealed with a product like Astro PFP FR EX Mortar or within Astro PFP FR Boards (fire batts).
• Duct Sleeves:
  • Astro DS Duct Sleeve: These are intended for use where plastic ventilation ducts pass through fire-rated compartment walls. The sleeve contains an intumescent material that expands in a fire, crushing the duct and sealing the opening. They are tested to BS476 Part 22 / EN1366-3 and can offer up to 2 hours fire rating (some specific sizes, like 220x90mm, may be 1 hour). Astro DS Duct Sleeves are suitable for retrofitting, requiring access from one side only, and must protrude from each side of the partition (e.g., by 25mm or 40mm depending on the version). Any small gaps around the installed sleeve should be sealed with intumescent sealant.

Astroflame also offers other relevant products like fire-rated boards (PFP FR Boards), mortars (PFP FR EX Mortar), and various intumescent sealants (e.g., Astro PFP FR Acrylic, Astro HPE Sealant for pipes and cables).

B. Protecta Firestopping Products

Protecta, a brand by Polyseam, offers a wide range of firestopping solutions. These include products specifically for pipe and duct penetrations, often designed to work in conjunction with their FR Board (fire batt) and EX Mortar systems.

• Pipe Collars:
  • Protecta FR Pipe Collars: These collars are designed to maintain the fire resistance of compartment walls and floors breached by plastic pipes and also some configurations of metal pipes (e.g., with combustible insulation). They consist of a coated circular steel shell (often red or white) with a fast-expanding graphite-based intumescent material. They are suitable for pipe sizes up to Ø315mm (and larger in some cases) and can achieve fire classifications up to 240 minutes for integrity and insulation. They are certified for various plastic pipe types (PVC-U, PVC-C, PE, HDPE, PP, etc.) and tested for U/U pipe end applications. For metal pipes, their function is to seal the void left by burnt-away combustible insulation. Installation involves fixing the collar to the substrate (drywall, timber, masonry, concrete) using standard screws.
• Pipe Wraps:
  • Protecta FR Pipe Wraps: These comprise a plastic-wrapped, graphite-based intumescent material – a type of fire pipe wrap. They react to heat to seal openings left by melting plastic pipes (PVC, PP, PE, ABS, Alupex), bundles of pipes, or cables, and also for metal pipes with continuous combustible insulation. They can be used for plastic pipes up to Ø400mm and for metal pipes with continuous combustible insulation. Fire classifications up to 240 minutes are achievable, allowing for solutions such as a 2 hour fire rated pipe wrap. The wraps are secured around the pipe with an attached sticker and can be cast into compartment walls and floors or fitted within Protecta FR Board or EX Mortar. They are available as pre-made sizes or in rolls.
• Duct Fire Protection:
  • Protecta FR Damper: These are fire-rated dampers for ventilation ducts passing through fire-rated compartment walls and floors (drywall, masonry, concrete, timber). They consist of a galvanised steel casing with horizontal steel blades treated with heat-expanding graphite. In a fire, the blades expand to seal off airflow, preventing fire and smoke spread inside and around the ventilation duct. They can achieve fire ratings up to EI 120 and are tested to EN 1366-12. Circular dampers are available up to Ø1250mm and rectangular versions up to 1200x1700mm.
  • Protecta FD Service Transit: This is a rectangular duct with a lid, made of steel with a graphite intumescent lining, approved for square plastic ducts and other services.
• Service Transits:
  • Protecta FR Service Transit / FF Service Transit: These are circular casings (high-temperature plastic or steel) with a graphite-based intumescent lining. They are designed for compartment walls and floors breached by continuous cables and plastic pipes. Ideal for situations where services might be added or changed later, or in tight spaces, they can be cast in, friction-fitted, or installed within larger apertures using FR Board or EX Mortar. Available in various lengths (150mm, 250mm, 400mm) to suit different construction depths and fire ratings up to 240 minutes.

Protecta also provides FR Board (fire batt), FR Coating (ablative), EX Mortar, and various sealants (FR Acrylic, FR Graphite) that are often used in conjunction with their pipe and duct firestopping solutions.

Table 4: Overview of Example Astroflame and Protecta Pipe/Duct Firestopping Products

Section 10: Fire Rated Construction Boards and Penetration Sealing: The Case of Marmox Fireboard

Modern construction often utilises specialised boards that offer multiple benefits, including inherent fire resistance. Marmox Fireboard is one such product, designed for a variety of internal and external applications, including wall and ceiling linings.

Marmox Fireboard: Composition and Properties

Marmox Fireboard is constructed with a core of Marmox Stone Wool (a type of mineral wool), which provides fire protection, sound absorption, and thermal insulation. The board is coated on its faces with a fibreglass mesh embedded in a cement polymer mortar, often featuring a unique honeycomb surface finish similar to their Multiboard range.

Key properties relevant to fire safety and general use include:

• Fire Resistance: Marmox Fireboard is certified A1 non-combustible according to the Euroclass system (BS EN 13501-1). This is the highest classification, indicating it will not significantly contribute to a fire. It has passed rigorous tests including EN 1182 (non-combustibility), EN 1716 (calorific value), and EN 13823 (single burn test).
• Thermal Insulation: The mineral wool core provides good thermal insulation (thermal conductivity typically around 0.037W/mK).
• Acoustic Insulation: The fibrous nature of the mineral wool core also offers sound absorption and decoupling properties.
• Weatherproof and Moisture Resistant: The stone wool core does not absorb moisture, making the board durable and suitable for wet environments or external applications.
• Lightweight and Workable: Despite its robustness, it is relatively lightweight and can be cut with standard tools, making installation easier.
• Surface Finish: The surface is designed to be an ideal substrate for plaster or render without requiring pre-treatment.

Marmox Fireboards are available in various thicknesses, commonly 20mm, 50mm, and 100mm. They can be fitted to masonry, timber, and steel frame constructions and are used for internal and external compartment walls and floors, ceilings (to prevent fire spread between floors), fire surrounds, and as part of External Wall Insulation (EWI) systems, even on buildings over 18 metres in height where regulations are particularly stringent.

(It is important to distinguish Marmox Fireboard (A1 rated) from Marmox Multiboard, which, while fire resistant, is stated as a Class E material in some contexts. Multiboard would have different limitations regarding its use in fire-critical applications, especially externally on taller buildings or in escape routes without an appropriate fire-resistant coating like plaster or render.)

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Firestopping Service Penetrations Through Marmox Fireboard 

While Marmox Fireboard itself boasts an A1 non-combustible rating and contributes significantly to the fire resistance of a wall or ceiling assembly, it is crucial to understand that any service penetrations (for pipes, ducts, cables, etc.) made through a Marmox Fireboard-lined construction must be appropriately firestopped. This is essential to maintain the overall fire compartmentation. An A1 fire-rated board alone does not automatically make penetrations through it fire-safe without specific, tested firestopping solutions for those penetrations.

Currently, specific tested details from Marmox for firestopping various service penetrations directly through their Fireboard are not widely available in the provided information. Therefore, a general best-practice approach, aligned with UK regulations and standards, must be followed:

• Select Tested Systems: Any firestopping product (e.g., pipe collars, intumescent wraps, sleeves, intumescent sealants, fire batts used in conjunction) intended to seal a penetration through a Marmox Fireboard wall or ceiling must be third-party tested and certified (e.g., to BS EN 1366-3). This testing must be for that specific type of service, its size, the nature of the penetration, and within a supporting construction representative of the Marmox Fireboard assembly.
• Compatibility: The chosen firestopping solution must be compatible with both the service material (e.g., plastic pipe, metal pipe, insulated duct) and the Marmox Fireboard itself, including its surface coatings.
• Manufacturer Guidance: Always adhere strictly to the installation instructions provided by the manufacturer of the chosen firestopping product. Additionally, consult any specific guidance Marmox may provide regarding making penetrations in their Fireboard and suitable methods for sealing them.
• Overall Assembly Performance: The goal is to ensure that the entire assembly – the Marmox Fireboard-lined structure plus the firestopped penetration – achieves the required fire resistance rating (e.g., EI30, EI60) for the compartment line.

Typical Approaches (General Principles):

• For smaller, individual pipe penetrations, appropriately sized and rated pipe collars or fire wraps for pipework would likely be considered. These should be fixed securely to or within the Marmox Fireboard (potentially with additional support or framing if required by the firestop manufacturer for non-rigid constructions) and sealed with compatible intumescent sealant. The fixing method for collars would need to ensure a robust attachment to the Fireboard and potentially the underlying structure.
• For larger or multiple service penetrations, a common approach in many fire-rated board constructions is to use an additional fire batt system (like those described in Section 8). This creates a localised, robust fire seal within the opening in the Marmox Fireboard. Services would then penetrate this secondary fire batt, sealed with appropriate collars, wraps, or sleeves tested for use in such batt systems.
• All annular gaps around services and firestopping devices must be fully sealed with a compatible, fire-rated intumescent or ablative sealant.

Given the A1 rating and robust nature of Marmox Fireboard, it provides a solid basis for creating fire-resistant constructions. However, the responsibility for ensuring that service penetrations are correctly firestopped to maintain that resistance lies with the specifier and installer, using proven, tested solutions. When in doubt, always seek technical advice from both the firestopping product manufacturer and Marmox.

Section 11: Navigating UK Standards and Regulations for Pipe Firestopping

Ensuring the correct specification and installation of fire-rated pipe protection is not just a matter of good practice; it is a legal requirement in the United Kingdom. This is governed by a framework of Building Regulations and supported by detailed British and European Standards.

A. UK Building Regulations Overview

In England and Wales, the Building Regulations 2010 set out the overarching legal requirements for building work. Practical guidance on how to meet these requirements for fire safety is provided in Approved Document B (Fire Safety). This document is split into two volumes: Volume 1 covers Dwellings, and Volume 2 addresses Buildings other than Dwellings. While specifics can vary, the core principles of fire safety and compartmentation are consistent.

A key requirement pertinent to firestopping is Requirement B3: Internal Fire Spread (Structure). This mandates that "The building shall be designed and constructed so that, in the event of a fire, its stability will be maintained for a reasonable period." Critically, it also states, "The building shall be designed and constructed so that unseen fire and smoke within concealed spaces in its structure and fabric is inhibited."

This directly relates to the need for effective fire compartmentation and the sealing of any penetrations through compartment lines formed by compartment walls and floors. Approved Document B explicitly states that all fire-rated elements must have their fire resistance reinstated if they are penetrated by services. Openings for such services must be kept as few and as small as practicable, and they must be appropriately fire-stopped. This also applies to joints between fire-separating elements, which must also be fire-stopped.

It is important to recognise that Approved Document B provides guidance. While following this guidance is the most common way to demonstrate compliance, it is not the only way. The ultimate responsibility for compliance rests with those carrying out the building work. Alternative solutions can be used if they can be demonstrated to meet the functional requirements of the Building Regulations and are agreed with the relevant Building Control Body, ideally at an early stage in the project.

B. Key British and European Standards (BS EN)

A number of British and European Standards underpin the testing, classification, and specification of fire-rated products for pipe penetrations:

• BS EN 13501-1: Fire classification of construction products and building elements. Part 1: Classification using data from reaction to fire tests. This standard is fundamental for understanding how materials themselves behave in a fire. It establishes the Euroclass system (A1, A2, B, C, D, E, F) for reaction to fire performance, where A1 is non-combustible and F is easily flammable. It also includes classifications for smoke production (s1, s2, s3 – low, medium, high) and flaming droplets/particles (d0, d1, d2 – none, some, high).
• BS EN 1366-3: Fire resistance tests for service installations. Penetration seals. This is the primary European test standard for assessing the fire resistance of penetration sealing systems. This includes those used for pipes, cables, and ducts passing through compartment walls and floors. The test methodology involves subjecting a representative sample of the penetration seal, installed in a supporting construction (e.g., a wall or floor), to standardised fire conditions (following the ISO 834 cellulosic temperature-time curve) and pressure regimes. Performance is evaluated based on the time for which the seal maintains:
  • Integrity (E): Preventing the passage of flames and hot gases, assessed by criteria such as no sustained flaming on the unexposed side, no ignition of a cotton pad, and no penetration by specified gap gauges.
  • Insulation (I): Limiting the temperature rise on the unexposed surface of the seal and adjacent areas to prevent fire spread by conducted heat. Test durations typically range from 30 minutes to 240 minutes (4 hours). Compliance is not merely about selecting a product with a "fire rating"; it's about ensuring that the product has been tested to the correct standard for the specific application – in this case, BS EN 1366-3 for penetration seals. A product might have an excellent "reaction to fire" classification under BS EN 13501-1 (e.g., be non-combustible) but could still perform poorly as a penetration seal if not specifically designed and tested for that complex scenario, which involves interaction with various services and the surrounding structure.
• BS 476: Fire tests on building materials and structures. This is an older series of British standards. While many parts have been superseded by European Norms, some parts, such as BS 476-20 (Method for determination of the fire resistance of elements of construction (general principles)) and BS 476-22 (Methods for determination of the fire resistance of non-loadbearing elements of construction), are still referenced or provide a basis for assessing products, particularly if they were tested before the full adoption of EN standards.
• BS 5422: Method for specifying thermal insulating materials... and BS 5970: Code of practice for thermal insulation of pipework...: These standards are primarily concerned with the thermal performance of insulation but are relevant where fire-rated insulation also serves a thermal purpose. They provide guidance on material specification and application, which can intersect with fire safety considerations.

The transition from national standards (like parts of BS 476) to European Norms (EN) aims to harmonise testing and classification across Europe. This requires professionals in the UK construction industry to be familiar with the current EN terminologies and methodologies, such as Euroclasses for reaction to fire and EI ratings for fire resistance. This ongoing evolution underscores the need for continuous professional development to stay abreast of the latest standards.

C. Understanding Fire Ratings (Integrity & Insulation)

Fire resistance performance is typically expressed in terms of Integrity (E), Insulation (I), and sometimes Loadbearing Capacity (R), followed by a time in minutes (e.g., 30, 60, 120). For penetration seals in compartment walls and floors, E and I are the most critical:

• E (Integrity): This refers to the ability of the firestopping system to prevent the passage of flames and hot gases from the fire-exposed side to the unexposed side for the specified duration. For example, E60 means the product maintains its integrity for at least 60 minutes.
• I (Insulation): This refers to the ability of the system to restrict the temperature rise on the unexposed surface to below specified limits for the duration. This prevents fire spread by conducted or radiated heat that could ignite materials on the non-fire side.
• EI (Integrity & Insulation): When a product is rated EI (e.g., EI60), it means it satisfies both the integrity and insulation criteria for that period. This is generally the most stringent requirement for fire-separating elements and penetration seals, as it addresses both direct flame/gas passage and heat transfer. Common ratings encountered include EI30, EI60, EI90, and EI120.

Table 3: Key UK Standards for Fire Rated Pipe Penetration Seals

Section 12: Best Practices for Selecting and Installing Fire Rated Pipe Protection

The successful firestopping of pipe penetrations hinges on two critical phases: the correct selection of the firestopping solution and its meticulous installation in accordance with tested configurations. Failure in either phase can compromise the fire compartmentation of a building.

A. Factors for Selecting Appropriate Solutions

Choosing the right firestopping product requires careful consideration of several interconnected factors:

• Pipe Material: This is a fundamental distinction.
  • Combustible pipes (e.g., PVC, PE, PP) will melt and deform in a fire, requiring a firestop (like a collar or a fire pipe wrap) that can crush the pipe and seal the void.
  • Non-combustible pipes (e.g., steel, copper) will not melt but can conduct significant heat. If uninsulated, they require fire-rated insulation to prevent heat transfer. If they have combustible insulation, this will burn away, requiring a wrap or collar to seal the resulting void.
• Pipe Diameter: Firestopping products are manufactured and tested for specific ranges of pipe diameters. It is essential to select a product that is appropriately sized for the pipe being sealed.
• Pipe Insulation: If the pipe is already insulated for thermal or acoustic reasons, the firestopping solution must be compatible.
  • Is the existing insulation combustible or non-combustible?
  • Some products, like insulated fire sleeves, are designed to maintain the continuity of existing insulation while providing the fire seal.
  • If the existing insulation is combustible (on either plastic or metal pipes), it may need to be removed at the penetration point and replaced with a fire-rated system, or a specific type of fire rated pipe wrap or collar designed for this scenario may be required.
• Required Fire Rating (Integrity & Insulation - EI): The firestopping system must achieve a fire rating (e.g., EI60, EI120, which could involve a 2 hour fire rated pipe wrap for relevant applications) that is at least equal to the required fire rating of the compartment wall or floor being penetrated.
• Type of Construction: The material of the compartment wall or floor (e.g., masonry, concrete, plasterboard drywall, timber construction, or specialised fire-rated boards like Marmox Fireboard) and its thickness will influence product selection. Some products, like certain intumescent wraps, are designed for installation within solid constructions, while others are suitable for drywall partitions or fire batt systems. The compatibility of the firestop with the specific construction substrate is paramount.
• Annular Space/Aperture Size: The size of the gap between the pipe and the edge of the opening in the structure must be considered. This annular space often needs to be filled with a compatible fire-rated sealant as part of the overall firestopping system. For larger openings, a fire batt system may be required.
• Service Conditions: The normal operating conditions of the pipe, such as temperature, exposure to moisture, or chemicals, should be considered to ensure the long-term durability and performance of the firestopping product.
• Third-Party Certification and Test Evidence: Crucially, the selected product must have been successfully tested to the relevant standard (e.g., BS EN 1366-3) for the specific application. This includes pipe type, size, orientation, supporting construction, and required fire rating. Always demand and review the third-party certification and associated test evidence.

B. General Installation Guidelines 

While the manufacturer's specific installation instructions for a product are always paramount, some general best practice principles apply:

• Surface Preparation: Ensure the pipe surface and the surrounding substrate (compartment wall or floor) are clean, dry, and free from dust, grease, loose materials, or any contaminants that could interfere with adhesion or performance.
• Correct Sizing and Fitting: Use the correctly sized product for the pipe diameter. Insulation or sleeves should fit snugly. Fire wraps for pipework should have the correct overlap as specified by the manufacturer.
• Positioning: The correct positioning of the firestop is critical. For pipe wraps, this often means ensuring an edge is exposed to the fire side for timely activation. Collars should be installed flush against the surface of the compartment wall or floor. Insulated fire sleeves should be cut and installed flush with the faces of the compartment wall or floor, or protrude as per the manufacturer's specification for certain applications (e.g., when used with fire batts or PVC services).
• Fixing: Fire collars must be securely mechanically fixed to the structure using the manufacturer's recommended type and number of fixings. Pipe wraps are typically secured using their integral self-adhesive tape. When fixing to or through fire batts, specific fixings (e.g., pigtail screws) may be required.
• Sealing Gaps: Any remaining annular gaps around the pipe or the firestopping device itself must be sealed with a compatible fire-rated sealant (e.g., intumescent mastic or acrylic sealant) or firestop compound to ensure a smoke-tight and fire-tight seal. This includes sealing around fire batts and where services penetrate them.
• Multiple Penetrations: If multiple services pass through a single large opening in a compartment wall or floor, specialised solutions such as fire-rated batts used in conjunction with appropriate collars, wraps, or sleeves will be required. The spacing between services and from the edges of the aperture is critical and must follow tested details.
• Follow Best Practice Guidance: Adhere to industry best practice, such as the "Golden Rules" for penetration seals outlined by organisations like the Association for Specialist Fire Protection (ASFP). These often include early engagement with manufacturers, using third-party certified products and installers, and ideally using a single manufacturer's system within an opening unless compatibility is proven through testing.

The "as tested" principle is fundamental in firestopping. Products and systems are fire-rated based on specific configurations tested in a laboratory. Any deviation from this tested configuration – be it the product itself, the type or size of pipe, the nature of the supporting construction, or the installation method – can potentially invalidate the fire rating and compromise safety. Installers must strive to replicate the conditions under which the product achieved its certification.

C. Common Mistakes and How to Avoid Them

A significant number of firestopping failures are attributable to human error or a lack of knowledge during specification or installation, rather than inherent defects in the products themselves. Common mistakes include:

• Using Non-Compliant or Untested Products: Selecting products without appropriate third-party certification or test evidence for the specific application.
• Incorrect Product for Pipe Type: For example, using a solution designed for plastic pipes on an uninsulated metal pipe without considering heat conduction, or vice-versa.
• Poor Installation Practices:
  • Incorrect positioning of wraps or collars (e.g., a fire pipe wrap recessed too far, collar not flush).
  • Missing or incorrect fixings for collars.
  • Inadequate sealing of annular gaps around the pipe or device, or around fire batts.
  • Using inappropriate materials for sealing gaps, such as standard silicone or, notoriously, "pink" expanding polyurethane foam which is often not suitably fire-rated for penetration sealing and can release toxic fumes.
• Incorrect Spacing: Insufficient spacing between adjacent services or between services and the edges of the opening, which can prevent the firestop from performing correctly. This is particularly critical when using fire batt systems with multiple penetrations.
• Damage by Other Trades: Firestopping installations can be damaged by subsequent trades working in the same area if there is a lack of awareness or coordination.
• Lack of Coordination Between Trades: This can lead to services being installed in a way that makes compliant firestopping difficult or impossible.
• Failure to Follow Manufacturer’s Instructions: This is a primary cause of ineffective firestopping.

Avoidance Strategies: The most effective way to avoid these mistakes is through a combination of:

• Using Competent Personnel: Employing third-party certified firestopping installers who have demonstrated their knowledge and skill.
• Adherence to Documentation: Rigorously following the manufacturer's installation instructions, data sheets, and the scope of application defined by the test evidence.
• Training and Awareness: Ensuring all relevant site personnel are aware of the importance of firestopping and the need to protect installed systems.
• Supervision and Inspection: Implementing robust site supervision and inspection regimes to verify correct installation before areas are closed off.

The interface between different trades and the sequencing of work on site are critical risk factors. Firestopping is often installed after mechanical and electrical services are in place. This necessitates careful planning and coordination to ensure that services are routed in a manner that allows for effective firestopping and that installed firestops are not subsequently compromised.

D. Importance of Manufacturer's Instructions and Certified Installers

Firestopping products are tested as complete systems. Their performance is contingent upon being installed exactly as they were during the fire test. Manufacturer's instructions detail these critical parameters.

Certified installers undergo training and assessment to ensure they have the competence to understand these requirements and apply them correctly in practice. Relying on such expertise is crucial for achieving compliant and effective fire safety.

Section 13: Ensuring Compliance: Certification and Marking

In the UK, demonstrating that firestopping products for pipe penetrations meet the required safety and performance standards involves a system of regulatory marking and independent third-party certification. These provide assurance to specifiers, installers, building control bodies, and end-users.

A. UKCA (UK Conformity Assessed) Marking

Following the UK's departure from the European Union, the UKCA marking is the product marking used for goods being placed on the market in Great Britain (England, Wales, and Scotland). It covers most product areas that previously required the CE marking.

For fire safety products, including fire-rated pipe collars, intumescent wraps, and insulation, the UKCA mark signifies that the product meets the necessary UK standards, regulations, and conformity assessment procedures. Affixing the UKCA mark is a manufacturer's declaration of compliance and demonstrates a commitment to quality and safety within the UK regulatory framework.

B. CE Marking

The CE marking indicates that a product complies with EU safety, health, and environmental protection requirements. It means the product can be legally placed on the market within the European Economic Area (EEA). For construction products, it signifies that the product is "fit for purpose" and will enable the finished construction works to comply with the essential requirements of the Construction Products Regulation (CPR).

While the UKCA mark is now the primary mark for Great Britain, CE marking may still be relevant for products sold in Northern Ireland or the EU. For a transitional period, some products could carry both marks or rely on CE marking if placed on the GB market before specific deadlines. It is important to note that CE marking, like UKCA marking, denotes compliance with minimum performance requirements and should not be confused with voluntary third-party quality marks.

The co-existence or transition between UKCA and CE marking can present complexities for manufacturers who supply products to both the UK and EU markets. This may potentially require adherence to two, albeit often similar, sets of regulatory and testing protocols, which could have implications for product availability and cost.

C. Importance of Third-Party Certification (TPC)

Beyond the mandatory regulatory markings, independent Third-Party Certification (TPC) plays a crucial role. It provides enhanced confidence in the performance and quality of firestopping products and their installation. Schemes run by accredited bodies such as Certifire, LPCB (Loss Prevention Certification Board), IFC Certification, and BM TRADA offer a more in-depth assurance.

• Product Certification: TPC for products typically involves:
  • Initial type testing of the product to relevant standards (e.g., BS EN 1366-3 for penetration seals).
  • Audits of the manufacturer's Factory Production Control (FPC) systems to ensure consistent quality and that manufactured products match the tested specification.
  • Ongoing surveillance, including re-testing or sample checking, to verify continued compliance. A third-party certified product gives specifiers and users greater confidence that it will perform as claimed in a fire.
• Installer Certification: TPC schemes also exist for installers of passive fire protection systems (e.g., FIRAS, LPCB, IFC Certification schemes). These schemes assess the competence of installation companies, ensuring they have the necessary knowledge, skills, and procedures to install products correctly and in accordance with the manufacturer’s instructions and test evidence. Given that incorrect installation is a primary cause of firestopping failure, the certification of installers is as critical as the certification of the products themselves. Using a third-party certified installer helps ensure that the specified fire performance is achieved on site.

The demand for UKCA/CE marking and, increasingly, voluntary third-party certification, reflects a broader industry trend towards demonstrating due diligence and achieving higher levels of assurance. Particularly in the wake of incidents like the Grenfell Tower fire, there is heightened scrutiny on the performance of building products and systems. Manufacturers and installers who invest in these certifications are better placed to demonstrate the quality and compliance of their offerings, which can be a significant factor in procurement decisions.

D. Documentation

Comprehensive documentation is essential to support compliance claims. Manufacturers should provide:

• Declaration of Performance (DoP) for UKCA and CE marked products, which provides information on the essential characteristics of the product.
• Certificate of Constancy of Performance (CoC) or similar conformity certificates issued by notified/approved bodies.
• European Technical Assessment (ETA) if the product is not covered or not fully covered by a harmonised European standard (for CE marking).
• Detailed test reports from accredited laboratories, demonstrating performance against relevant standards like BS EN 1366-3.
• Clear installation instructions and scope of application documents.

This documentation provides the necessary evidence that the firestopping solution is suitable for its intended purpose and meets the required performance levels.

Buy Fire Rated Pipe Insulation

Section 14: Maintaining Fire Compartmentation: The Vital Role of Pipe Firestopping

The effective firestopping of pipe penetrations using appropriately specified and correctly installed fire-rated insulation, fire wraps for pipework, and collars is not merely a technical detail. It is a fundamental pillar of a building's overall fire safety strategy. These systems play a critical and often unsung role in maintaining the integrity of fire compartmentation, which is designed to save lives and protect property.

By sealing the breaches created by service pipes passing through fire-resistant compartment walls and floors, these firestopping solutions perform several vital functions in the event of a fire:

• Slowing or Preventing Fire and Smoke Spread: Their primary purpose is to contain the fire within the compartment of origin, preventing or significantly delaying its spread to other parts of the building. This also applies to the spread of smoke and toxic gases, which can often be more dangerous to occupants than the flames themselves.
• Protecting Escape Routes and Aiding Evacuation: By limiting fire and smoke spread, firestopped penetrations help to keep escape routes (such as corridors and stairwells) tenable for longer, providing occupants with crucial additional time to evacuate safely.
• Reducing Property Damage: Confining a fire to a smaller area naturally leads to a reduction in the overall damage to the building structure and its contents.
• Facilitating Safer Firefighting Access: Compartmentation helps create more manageable conditions for firefighters, allowing them to approach and tackle the blaze with reduced risk.

The integration of robust pipe firestopping with other passive fire protection measures – such as fire doors, fire-rated partitions, cavity barriers, and intumescent coatings on structural steel – creates a comprehensive and layered defence system. Each element of PFP is designed to work synergistically. The failure of one component can potentially compromise others. For example, a fire door can only effectively hold back fire if the compartment wall it is set into, including any pipe penetrations through that wall, maintains its own fire resistance.

It is crucial to understand that firestopping is not a "fit and forget" solution. The integrity of these installations must be preserved throughout the building's operational life. Building owners and managers have a responsibility, often under legislation such as the Regulatory Reform (Fire Safety) Order 2005 in England and Wales, to ensure that fire safety measures are maintained in an effective state.

However, because firestopping systems are frequently concealed within compartment walls and floors, or service voids, their importance can be overlooked. They can be inadvertently damaged or removed during subsequent building work, maintenance activities, or refurbishments if personnel are not adequately trained or aware of their critical function.

Regular inspections, particularly after any alterations or the installation of new services, are therefore essential to ensure that fire compartmentation remains intact. Any deficiencies found must be promptly rectified by competent persons using appropriate, tested solutions.

The responsibility for effective firestopping is a shared one, extending across the entire lifecycle of a building. It begins with correct design and specification, moves through competent installation by skilled contractors, and continues with diligent management and maintenance by building operators. A breakdown at any point in this chain can have severe consequences.

Furthermore, as building service technologies