The "Dry Trade" Revolution: FyreWrap Insulation vs. Fire Spray
Fire spray was the standard practice for decades. This nasty “wet trade” method took a lot of planning, covering up nearby services, and a long time to cure. It made the structure very heavy and often stopped further trades from happening nearby. It was also very hard to check the thickness and quality of a spray coating, especially in confined locations. This often led to expensive re-works during the certification stage.
Everything changed when FyreWrap insulation came out. The blanket is comprised of bio-soluble fibres and has a foil face. It is flexible and fireproof. It is a “dry trade,” not a spray. It can be quickly cut, wrapped around the duct, and secured without making the mess or dust that comes with spray-applied materials.
Trafalgar FyreWrap is five times lighter than regular vermiculite sprays. This weight loss makes the building’s structure far less stressed and makes it easier to install the hanger support systems needed for the ductwork. Its silver foil finish is important since it gives the product a clean, attractive look and lets you see right away that it’s high quality and covers well.
Strict rules: following the law and AS 1530.4-2014
In the area of fire safety, guessing is not an option; compliance must be checked. The current standard for compliance in the NCC is strict testing to AS 1530.4-2014, which is the standard for fire tests on building materials.
Older duct protection systems might only have tests based on the old 2005 version of the standard, or even worse, they might not have comprehensive system tests for all possible fire situations (internal vs. external fire).
FyreWrap has been completely tested to AS 1530.4-2014. This thorough testing process makes sure it fulfils the required Fire Resistance Levels (FRL) of up to -/120/120 (2 hours) or -/180/180 (3 hours). Building certifiers and engineers can feel safe about using Trafalgar FyreWrap since the test data is up-to-date, strong, and easy to find. This means that there is no doubt about getting final building permission.
Kitchen exhaust and smoke spill systems: Performance Matters
Distinct ducts have distinct jobs and face different fire dangers. A duct fire wrap system that works well must be flexible to change.
Kitchen exhaust (grease) ducts
- These are a special problem. A fire that starts in a duct full of grease needs to be put out, and the heat transfer needs to be limited so that neighbouring flammable things don’t catch fire outside the duct.
- FyreWrap is perfect for this use because it can handle high temperatures and has no space for flammable materials.
Smoke Spill and Stair Pressurisation Ducts
- These systems need to keep working during a fire. They either guard escape routes (such stairwells) or actively pull smoke out of the structure.
- FyreWrap insulation is tested for “external fire,” which means that the duct will still work even if there is a fire in the ceiling void. This helps people get out of the building and gives firemen access.
Trafalgar Fire (Tfire) has made sure that its system is tested and approved for all of these important uses, which makes it a very flexible option.
Important Things to Know About Installing FyreWrap
If you don’t install the best product in the world correctly, it won’t reach its rated FRL. A correct and certified FyreWrap installation is very important. The following major installation parameters are what the system’s testing to AS 1530.4 is based on:
- The 75mm Overlap: All joints, whether they are circumferential (around the duct) or longitudinal (along the duct), must have at least 75mm of overlap. This is not open to discussion, as it keeps heat from getting to the duct at the seam.
- Compression at Overlaps: At these overlaps, the wrap must be compressed, not just sitting there.
- Ways to Fix: The wrap is usually held in place with 12.7mm steel banding or, as needed, stainless steel pins and speed clips. You have to use these in the exact way that was tested.
- Pre-Wrapping for Efficiency: One big benefit is that Trafalgar FyreWrap can be put on the duct sections in a controlled environment away from the job site. Pre-wrapping makes logistics easier and speeds up the construction schedule on site.
When fire wraps don’t pass an inspection, it’s almost often because they were installed poorly, there were gaps in the blanket, the overlaps weren’t big enough, or the strapping tension was wrong.
The problem with the access panel, maintenance, and durability
Ducts, especially those that vent out of the kitchen, need to be cleaned often to keep grease from building up. A permanent, seamless wrap makes it impossible to get to the maintenance without ruining the fire rating.
The FyreWrap Access Panel, which is patented, solves this problem for the FyreWrap system. These access doors have been tested to keep the full FRL (-/120/120 or -/180/180) while making it easy for maintenance workers to take off a part of the insulating blanket and open the duct.
Also, Trafalgar FyreWrap is naturally strong. It doesn’t shake, is Greenguard-listed for microbiological resistance (to keep mould from growing), and stays strong for the life of the structure.
The "Green" Factor: Health and Sustainability
More and more, modern building projects put the health of workers on site and sustainability (Green Star ratings) at the top of their lists.
- Insulfrax® technology: FyreWrap is made with cutting-edge Insulfrax® technology. This bio-soluble fibre core is less dusty and safer to work with than older ceramic or mineral wool products. This makes it much less irritating for installers.
- Indoor Air Quality: Trafalgar FyreWrap insulation also has low levels of volatile organic compounds (VOCs), which meets strict regulations for indoor air quality for people who live and work there. This makes it the best choice for hospitals, daycare facilities, and high-end commercial buildings.
FyreWrap is the standard in Australia for protecting ducts, and it didn’t happen by chance; it was planned. It fixes all of the biggest problems with classic vermiculite systems. It is easier to install, lighter, and, most significantly, it meets the strict performance standards set by modern legislation.
Trafalgar Fire (Tfire) has given the industry a solution that makes sure safety, speeds up construction, and makes sure compliance by focusing on a complete, integrated system that includes the specific FyreWrap installation details, validated access panels, and full compliance with AS 1530.4-2014. Trafalgar FyreWrap is the best in the business when it comes to fire safety, and for good reason.
Questions and Answers
1. How does FyreWrap stack up against vermiculite fire spray for ductwork?
FyreWrap is a “dry trade” solution, while vermiculite spray is a “wet trade.” The main benefits of FyreWrap are that it is up to five times lighter, doesn’t need to dry, and doesn’t make a mess on the job site. This lets other trades keep working nearby without having to set up exclusion zones. Also, the foil finish of FyreWrap makes it easier for certifiers to check the product’s quality, while spray paint can crack, flake, or be put in uneven layers.
2. Is one layer of FyreWrap enough to get a fire rating of two hours?
The number of layers needed in Australia depends on the Fire Resistance Level (FRL) needed and the use. Some systems are tested for a 2-hour rating (-/120/120) with just one layer of 38mm FyreWrap. However, some high-risk situations, such some kitchen exhaust setups or exterior fire threats, may need a double-layer system to fulfil AS 1530.4-2014 or international standards like ASTM E2336. Always check the Trafalgar Fire (Tfire) technical manual for your type of duct.
3. Is it possible to attach FyreWrap with "zero clearance" on wood or steel?
Yes. One of the best things about FyreWrap insulation is that it has been tested to make sure there is no space between it and anything that could catch fire. This means that the wrapped duct can touch wood frame, gypsum board, or other building services without the risk of heat transfer creating a fire. In compact places with ceilings that are too low to allow for the normal 300mm–600mm clearance needed for uninsulated ducts, this is a very important benefit.
4. What happens if the FyreWrap foil rips while you are putting it up?
Reinforced aluminium foil tape can be used to fix small tears in the aluminium foil wrapping. To keep the core sealed, the tape should go at least 50mm past the edges of the tear. But if the interior bio-soluble fibre core is broken or squished, that part needs to be replaced. Keeping the foil “jacket” in good shape is important for keeping moisture out and keeping the core from soaking up grease in kitchen exhaust applications.
5. How do you make sure that the access panel you install meets fire safety standards?
You need to employ a unique FyreWrap Access Panel system to stay in compliance. You can’t just cut a hole in the wrap and the duct. These unique panels have a duct door that can be opened and closed easily, and a matching fire-rated cover made of FyreWrap materials. This keeps the whole system’s AS 1530.4 integrity and insulation rating while yet letting the duct interior be cleaned and checked on a regular basis, as required.
