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Astroflame PFP FR EX Mortar | Fire Rated Compound
Astroflame PFP FR EX Mortar | Fire Rated Compound
Astroflame PFP FR EX Mortar | Fire Rated Compound
Astroflame PFP FR EX Mortar | Fire Rated Compound

Astroflame PFP FR EX Mortar

AST5363

A dry white powder consisting of inorganic compounds and perlite that, when mixed with water, the compounds form a highly thermally insulating fire sealing compound to prevent the spread of fire and smoke through openings in fire rated walls and floors, including openings formed around building service penetrations.

The intended application for this product must be checked with our Technical Team to ensure it has been tested prior to purchase/use.

  • Classified in walls and floors of concrete, brick, gypsum etc
  • Suitable for cables, bundled cables, cable racks, cable trays, steel, copper, alupex and plastic pipes
  • Simple to apply leaving a very smooth finish
  • High degree of mechanical resistance; the seal is load bearing without reinforcement
  • No priming necessary prior to application in most building material substrates however metal services in contact with the seal must be corrosion protected
  • Suitable for most surfaces, included concrete, bricks, Leca, steel, plastic etc, but not suitable to fitting of doors or in service openings that involve movement
  • Certified for use in walls (but recommended to use PFP FR Boards for these applications)
  • Fully set within 1 hour
  • Near-unlimited storage time
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Description

Astroflame PFP FR EX Mortar, a dry white powder consisting of inorganic compounds and perlite that, when mixed with water, the compounds form a highly thermally insulating fire sealing compound to prevent the spread of fire and smoke through openings in fire rated walls and floors, including openings formed around building service penetrations.

Astro PFP FR EX Mortar will also maintain the acoustic design performance in walls and floors. Astro PFP FR EX Mortar expands approx. 1% by hydraulic action during curing ensuring a very tight seal around the service penetrations and the surrounding opening apertures.

Easy to sand or drill, the compound dries to an off-white colour which may be painted.



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Features & Benefits


  • Classified in walls and floors of concrete, brick, gypsum etc
  • Suitable for cables, bundled cables, cable racks, cable trays, steel, copper, alupex and plastic pipes
  • Simple to apply leaving a very smooth finish
  • High degree of mechanical resistance; the seal is load bearing without reinforcement
  • No priming necessary prior to application in most building material substrates however metal services in contact with the seal must be corrosion protected
  • Suitable for most surfaces, included concrete, bricks, Leca, steel, plastic etc, but not suitable to fitting of doors or in service openings that involve movement
  • The product is certified for use in walls but it is recommended to use PFP FR Boards for these applications
  • Fully set within 1 hour
  • The fire performance specification of the compound has been derived when the seal has been left to cure for 1 month
  • Nearly unlimited storage time



Sound Insulation


Description Sound Reduction
Single sided cast ≥ 50 mm thick as linear seal Rw 64 dB
Double sided cast ≥ 25 mm thick as linear seal Rw 64 dB
Single sided cast ≥ 50 mm thick as large seal Rw 48 dB
Double sided cast ≥ 25 mm thick as large seal Rw 48 dB

Astro PFP EX Mortar has been tested at BM Trada (UKAS accredited); according to EN ISO 10140-2:2010.



Resistance to Fire


Construction Description Classification
Flexible walls comprise gypsum, masonry, aerated concrete or concrete Up to 2400 mm wide by 1200 mm high blank seal with double sided 25mm Astro PFP FR EX Mortar on 25mm cast board EI 120 (E 120)
Rigid walls comprise masonry, aerated concrete or concrete, within walls or between the head of walls and the soffit of floor slabs Up to 2400 mm wide by 1200 mm high blank seal with single sided 50mm Astro PFP FR EX Mortar on 50mm cast board EI 120 (E 180)
Up to 2400 mm wide by 1200 mm high blank seal with single sided 100mm Astro PFP FR EX Mortar EI 240 (E 240)
Rigid floors comprise aerated concrete or concrete within floors or between floors and walls Up to 2400 mm by 1200 mm blank seal with 50mm Astro PFP FR EX Mortar on top of 50mm cast board EI 180 (E 180)
Up to 2400 mm by 1200 mm blank seal casted with 100mm Astro PFP FR EX Mortar EI 240 (E 240)

The cast board comprise stone wool with density ≥ 150kg/m3.

Please read the Installation Instructions before usage.



Additional Aperture Sizes in Floors


Under EN 1366-3 rules, results from tests in floors with a penetration seal length of minimum 1m apply to any length as long as perimeter length to seal area ratio is not smaller than that of the test specimen. The following aperture sizes are therefore allowed where 2400 x 1200 mm is described in this data sheet and in the installation instructions.

Maximum Aperture Sizes within Floors or between Floors and Walls Sound Reduction
1200 mm width x 2400 mm length (tested)
1100 mm width x 2900 mm length
1000 mm width x 4000 mm length
900 mm width x 7000 mm length
≤ 800 mm width x ∞ (infinite) length

Astro PFP FR EX Mortar has been subject to concentrated load and impact tests in floors according to ETAG 026-2 and EOTA TR001 Clause 2. The tests were conducted on the minimum allowed cast depth of 100mm.

According to the loading limits in the table below, reinforcement is not necessary, however it is highly recommended that the edges of the aperture are brushed free of any dust or loose particles and that any contamination is washed away using clean water. Moistening the edges well before casting will improve adhesion.

Astro PFP FR EX Mortar should not be cast in surface treated concrete. The mortar must be mixed to a thick but fluid mass at a rate of approx. 2 parts of powder to 1 part water. Maximum loadbearing performance will be achieved 28 days after casting.

Test results:

Test in 1500x1000mm frame Results
Soft body impact, serviceability 500Nm
Soft body impact, safety in use 700Nm
Hard body impact, serviceability 6 Nm
Hard body impact, safety in use 10 Nm
Concentrated load to ETAG 26-2 15 kN



Curing Times


Application Temperature Cure time
For filler 3.5 to 1 mix 0 °C 19 minutes
10 °C 18 minutes
20 °C 17 minutes
30 °C 16 minutes
40 °C 15 minutes
For casting 2 to 1 mix 0 °C 40 minutes
10 °C 35 minutes
20 °C 30 minutes
30 °C 25 minutes
40 °C 20 minutes

Astro PFP FR EX Mortar was mixed with an electric mixer for 90 seconds with a 100mm diameter paddle. Note the greater the sheer/agitation generated in the mixing process the quicker the mortar will set. Astro PFP FR EX Mortar is designed to be a quick curing system for professional installers where fast application times is of the highest importance. For slower cure, a retardant can be added to the dry mortar powder (sold separately).



Emission Data (indoor air quality)


Application Temperature Cure time
TVOC 12 μg/m3 < 5 μg/m3
TSVOC n.d. < 5 μg/m3
VOC w/o NIK n.d. < 5 μg/m3
R Value n.d. < 1
Formaldehyde 7.1 μg/m3 n.d.
Acetaldehyde < 3 μg/m3 n.d.
Sum for+ace < 0.006 ppm n.d.
Carcinogenic < 1 μg/m3 < 1 μg/m3
n.d. or < means not detected  

Astro PFP FR EX Mortar complies with the requirements of GEV and the results correspond to the EMICODE emission class EC 1PLUS which is the best possible environmental and indoor hygiene health protection mark. Tested by Eurofins Product Testing, report number G12874B.



Pipe End Configurations


When testing pipes, one can choose not to cap (or close) the pipe, or cap the pipe inside the furnace, or outside the furnace, or on both sides. The configuration chosen depends on the intended application of the pipe and/or the installation environment.

The code defining if a pipe is capped is stated after the fire classification. For instance EI 60 C/U which means the pipe was capped inside the furnace, and uncapped outside the furnace. The test configuration defines the approvals possible.

Our engineering judgment based on EN 1366-3:2009 are:

Intended use of pipe Pipe end condition4
Rainwater pipe, plastic At drainage U/U1
Not at drainage C/C2
Drainage or sewage pipe, plastic Ventilated drain U/U1
Unventilated drain U/C1
Drain w/water trap U/C1
Not at drainage C/C2
Pipe in closed circuit (water, gas, air, electricity etc.) C/C22
Flue gas recovery system pipe, plastic U/C1
Pipe with open ends and ≥ 50cm length on both sides, plastic U/U2
Pipe supported by suspension system, metal Fire rated support C/U1
Non-fire rated U/C1
Waste disposal shaft pipe, metal U/C1

  1. Suggested in EN 1366-3:2009
  2. Astroflame’s judgment based on tests
  3. Metal pipes should have fire rated support
  4. U/U classified fire seals cover C/U, U/C and C/C. C/U classified fire seals cover U/C and C/C. U/C classified fire seals cover C/C



Technical Data


Technical Data
Condition Powder ready for mixing with water
Product consumption at 2:1 mix Approx. 3.42 bags per m2 @ 50mm depth Approx. 6.83 bags per m2 @ 100mm depth
Dry density About 900 kg/m3 after full cure
Flash point None
Reaction to fire Class A1 according to EN 13501-1
Hardened Less than 1 hour depending on the local climate
Totally hardened Up to 30 days depending on thickness and temp.
Flexibility None
Durability/service Class Z2
Thermal conduct. 0.051 W/mK
Working life 30 years
Storage No particular limit for unopened bags in dry places with storage temperatures between 5˚C and 30˚C
Compatibility Suitable for use with most materials, but should not be used in direct contact with metals that may corrode
Limitations Should not be used in permanently damp areas or in moving joints
Classification CE-marked - Fire seal for fire rated openings and penetrations class EI 240
Colour Off white



Installation


Please refer to the Technical Data Sheet for more in-depth installation information including illustrations and classifications for application of the following:

Installation Page
Cables and cable trays in floors Page 2-3
Steel pipes in floors Page 3-5
Copper pipes in floors Page 6-7
Alupex pipes in floors Page 7-8
Plastic pipes in floors Page 8-10
Composite pipes in floors Page 10-12
Conduits in floors Page 12
Cables and cable trays in masonry or concrete walls Page 12-13
Steel pipes in masonry or concrete walls Page 13-15
Copper pipes in masonry or concrete walls Page 15
Alupex pipes in masonry or concrete walls Page 15
Plastic pipes in masonry or concrete walls Page 15-16
Cables and trays in drywalls, masonry or concrete walls Page 16
Steel pipes in drywalls, masonry or concrete walls Page 16-17
Copper pipes in drywalls, masonry or concrete walls Page 17
Alupex pipes in drywalls, masonry or concrete walls Page 18
Plastic pipes in drywalls, masonry or concrete walls Page 18-19

 

Minimum separations and limitations

Services can be sealed as specified in the detailed drawings. An aperture can include several services, and they may also be different. The minimum permitted separation between adjacent seals/apertures is 200mm. Services should be a minimum of 30mm from seal edges. Services within the system Astro PFP FR EX Mortar seal do not require a minimum separation, except pipes where combustible pipe insulation penetrates the seal and plastic pipe penetrations, which should be a minimum of 30mm from other services in the aperture. The total amount of cross sections of services (including insulation) should not exceed 60% of the penetration area.

 

Supporting constructions

Flexible walls must have a minimum thickness of 100 mm and comprise steel studs or timber studs*) lined on both faces with minimum 2 layers of 12.5 mm thick boards. Rigid walls must have a minimum thickness of 100 mm and comprise concrete, aerated concrete or masonry, with a minimum density of 650 kg/m 3 . Rigid floors must have a minimum thickness of 150 mm and comprise aerated concrete or concrete with a minimum density of 650 kg/m 3 . The supporting construction must be classified in accordance with EN 13501-2 for the required fire resistance period.

*Timber studs: no part of the penetration seal may be closer than 100 mm to a stud, and minimum 100 mm of insulation of class A1 or A2 according to EN 13501-1 must be provided within the cavity between the penetration seal and the stud.

 

  1. Ensure the faces of the aperture opening are free of dust and any other contaminants. The faces may be moistened for better adhesion.
  2. If the mortar seal is required to be load bearing, please see instructions in the Technical Data Sheet.
  3. Bare metal pipes passing through the seal must be protected against corrosion using a suitable primer/protection system.
  4. When sealing drywalls the mortar should be flush with the surface of the wall on both sides.
  5. When sealing masonry or concrete constructions, the seal can be positioned to either side of the construction or anywhere in between.
  6. When installing Astro PFP FR EX Mortar in hollow floor slabs or boards, level the fire seal with the soffit side. Ensure there is sufficient thick- ness of concrete below the void for the depth of mortar. Where this is not the case, tubular voids should be filled with stone wool normally the same thickness as the depth of the floor slab. Alternatively, simply fire seal on both sides.
  7. Install a stone wool shutter board where is necessary to achieve the required thickness of mortar (see the drawings on pages 2-19). Make sure that this achieves a very tight seal – any small openings should be sealed with Astro PFP FR Acrylic.
  8. Pour clean water into a suitable mixing vessel and add the mortar to obtain the required consistency. Mix steadily at low speed and ensure that any lumps of powder are fully dispersed. Always add the mortar to the water, do not reverse this mixing process. For different mix ratios and drying times, please refer to the Technical Data Sheet.
  9. Once the desired consistency is achieved pour or trowel the mortar onto the shutter board making sure that it flows into all corners and around services. Apply a firm pressure to the mortar to eliminate any trapped air bubbles. Build up to the required depth.

 

Test Standards

This Installation Instruction is based on the product’s European Technical Assessment issued in accordance with regulation (EU) No 305/2011 on the basis of EAD 350454-00-1104, September 2017.



IMPORTANT FIRE PRODUCTS NOTICE: The information displayed on this website should be used as a guide ONLY and our Technical Department should be contacted to obtain a tailored specification and any advice necessary before you place an order for fire protection products. Fire protection products are non-returnable except in accordance with Condition 8 of the Terms and Conditions and should be applied only by an individual with the necessary expertise and experience. We will not be held liable for any resulting damage to property, human life or monetary costs incurred due to the incorrect specification you have prepared or use of fire protection products caused by your negligence, including your failure to have contacted us to obtain the relevant advice/specification.

Product Details
5363-884426

Data sheet

Manufacturer
Astroflame
For Use By
Professional Use
For Use On
Fire rated floors and walls
Cables
Concrete
Brick
Gypsum
Copper
Steel
Plastic
Alupex
Leca
Application Method
Trowel
Sheen
Smooth
Colour
Standard / Ready Mixed
Pack Size
20L
Coverage
Approx. 3.42 bags per m2 @ 50mm depth Approx. 6.83 bags per m2 @ 100mm depth
Shelf Life (from date of manufacture)
Unlimited
UN Number
N/A
Fully Cured
Up to 30 days depending on thickness and temp.
Hard Dry
Less than 1 hour depending on the local climate
Colour(s)
Standard Colours
Suitable For Use On
Concrete
Suitable For Use On
Plastic
Suitable For Use On
Brick
Suitable For Use On
Steel
Suitable For Use On
Copper
Suitable For Use On
Gypsum
Suitable For Use On
Cables
Suitable For Use On
Alupex
Suitable For Use On
Leca
Suitable For Use On
Fire Rated Floors
Suitable For Use On
Fire Rated Walls
Finish
Smooth
Application Method
Trowel
Manufacturer
Astroflame
Usages
Fire Resistance
Product Usage Type
High Strength Mortar
Colour Family
Off-White
Fire Rating
120 Minutes
Fire Rating
240 Minutes
Fire Rating
180 Minutes
Classification
CE
Attachments
Download


Customer agrees that before placing an Order, Customer has read and understood the most up to date Product Data Sheet for the Product. Where we have access to the Product Data Sheet from the manufacturer, we will either provide a copy on request, or include a link to the Product Data Sheet available on the manufacturer’s website. Customer further agrees that we have no liability for any errors or omissions contained within the Product Data Sheets. For more information, please see our Terms & Conditions of Sale.

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IMPORTANT SHIPPING & DELIVERY INFORMATION

Astroflame PFP FR EX Mortar is only available with the shipping and delivery timescales listed below - please do not contact our Customer Support Team with enquiries about alternative or earlier shipping and delivery times.

Saturdays and Sundays, as well as Bank Holidays, are not classed as working days.

Orders placed after the cut-off for this product will not be processed for earliest dispatch until 9am the next working day.

All delivery costs below are excluding VAT