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How to install Aestuver tunnel fire protection systems?

27/01/2025

Introduction

Tunnel fire protection systems designed, certified and manufactured under Aestuver brand provide reliable solutions for rail and road tunnels. Ensuring the safety and integrity of tunnels is paramount, and one of the most critical aspects of this is the installation of fire protection systems. These systems are designed to prevent the spread of fire, protect structural integrity, and ensure the safety of occupants and emergency responders.


This guide provides a comprehensive overview of the installation process for Aestuver fire protection systems for tunnels, focusing on best practices, essential tools, and key considerations. Whether you're a seasoned professional or new to the field, this article will equip you with the knowledge needed to effectively install these vital systems. At this point we assume that you already selected a suitable Aestuver fire board based on the project specifications and tunnel fire curve.

 

Importance of Fire Protection Systems for Tunnels

Tunnels are unique structures that require specialized fire protection systems to safeguard against potential fire hazards. These systems are designed to prevent the concrete spalling, spread of fire, protect structural integrity, and ensure the safety of occupants and emergency responders. Proper installation is crucial to achieving these objectives. Fire protection systems in tunnels are essential because they help to contain and control fires, minimize damage to the tunnel structure, and provide safe evacuation routes for people. Additionally, they protect critical infrastructure and reduce the risk of catastrophic failures that could result in significant economic losses and human casualties.

 

What are the Aestuver tunnel fire protection systems?

Aestuver fire protection systems for tunnels are passive methods of fire protection. These systems consist of certified and fire tested materials like Aestuver Tx fire boards, cover strips, fixings, FPM mastic and supporting frame.

Pre-Installation Considerations

Compliance with Standards and Regulations
Before you begin the installation please ensure that you comply with local standards, norms, safety regulations, and construction codes. Adherence to these guidelines is mandatory to avoid substandard installations and potential safety hazards. Compliance with standards ensures that the fire protection system will perform as expected in the event of a fire.
It also helps to avoid legal liabilities and ensures that the installation meets the requirements of insurance companies and regulatory authorities. Installers should familiarize themselves with relevant standards, project specification requirements and local building codes.

 

Personal Protective Equipment (PPE)

Safety is paramount during the installation process. All personnel involved must wear appropriate PPE as required by health and safety regulations, such as, but not limited to safety goggles, gloves, helmets, and other necessary protective gear. PPE protects workers from potential hazards such as falling objects, sharp edges. It is essential to ensure that all PPE complies with national standards and is suitable for the specific tasks being performed. Regular training and safety briefings should be conducted to ensure that all personnel are aware of the proper use and maintenance of PPE.

 

Storage and Handling of Fire Protection Boards

 

Storage of Tunnel Fireproofing Boards on Construction Site

Aestuver fire protection boards should be stored flat on a level surface to prevent deformation and damage. They can be stored outdoors but must be protected from excessive moisture. Proper storage is crucial to maintaining the integrity and performance of the fireproofing boards. It is also important to ensure that the storage area is clean and free from debris that could damage the boards.

 

Handling on Construction Site

Aestuver fire boards should be transported horizontally using forklifts or other appropriate plant or vehicles. Individual fire protection panels should be carried upright to avoid damage. Proper handling techniques are essential to prevent damage to the fire boards during transportation and installation. Workers should use appropriate tools and equipment, such as panel lifters or carriers, to handle the boards safely. It is also important to avoid bending, vibration, or collision that could cause damage to the fire boards.


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How to cut fire boards?

Fire protection boards can be cut using conventional woodworking machines. For precise cuts, we recommend using carbide-tipped saw blades with alternating teeth. Dust can be minimized by using saw blades with fewer teeth and lower speeds. Cutting and processing the fireproofing boards accurately is essential to ensure a proper fit and effective tunnel fire protection system. We recommend to set up a dedicated sawing station with appropriate dust extraction systems to minimize dust exposure.

 

Specific Tools and Equipment

Standard Tools

  • Hand Saw: Used for cutting fire boards to size.
  • Spirit Level: Ensures that fire boards are installed level and plumb.
  • Hammer: Used for driving nail anchors and other fasteners.
  • Soft-face Hammer: Prevents damage to the board surface when driving fasteners.
  • Measuring Tapes: Essential for accurate measurements.
  • Electric Screwdriver: Speeds up the installation process.
  • Hammer Drill: Used for drilling holes in concrete and other hard surfaces.
  • Angle Grinders: Used for cutting and shaping boards.
  • Cordless Screwdriver: Provides mobility and convenience.
  • Chalk Line: Used for marking straight lines.
  • Rope: Used for securing boards during transportation.
 

Specific Tools

  • Plunge Cut Track Saw and Vacuum: Provides precise cuts and minimizes dust.
  • Stapler Gun: Used for fastening backing strips to fire boards.
 

Additional Equipment

Depending on the construction site conditions, additional equipment such as scissors lifts, platforms, and vacuum lifters may be required. These tools and equipment help to ensure a safe and efficient installation process. Scissors lifts and working platforms provide access to high areas, while vacuum lifters make it easier to handle heavy boards.

 

Aestuver Tunnel Fire Protection System Installation Process

 

Surface Preparation

The surface for the fire protection boards should be even, flat, and dry. Any protruding items like screws and nails must be removed. Part of the Aestuver tunnel fire protection system are backing strips. These are thin strips of Aestuver fire board that help fixers mitigate the uneven installation substrate.
Proper surface preparation is essential to ensure a secure and stable fix. The surface should be checked for cracks, leakages, and other imperfections that could affect the performance of the tunnel fire protection system.

 

Anchoring

Anchors are used to fix the fire boards to the tunnel structure. There are three types of anchors:
  1. Nail Anchors with Nail Head: Installed by drilling a hole through the board and hammering the anchor into place. Examples are Fischer FNA II or Hilti HFB-R
  2. Nail Anchors with Nut: Installed by drilling a hole through the board, inserting the anchor, and securing it with a nut.
  3. Concrete Screws: Installed by drilling a hole through the board and driving the screw into the concrete, for example, Etanco screws.
 
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Nail Anchors with Nail Head Nail Anchors installed with percussion tool Concrete Screws
     



Each type of anchor has specific installation instructions that must be followed to ensure proper fixation. It is important to use the correct anchor type and size for the specific application and to follow the manufacturer's installation guidelines. Proper anchoring ensures that the fire boards are securely attached to the tunnel structure and can withstand the forces and stresses they may encounter.

 

Joint Design and Surface Treatment

 

Joint Design
Fire boards are installed butt-jointed with a gap width of ≤ 2 mm. Wider gaps can be filled with assembling mortar or FPM mastic. Proper joint design is essential to ensure a continuous and effective fire protection barrier. Butt joints should be tight and free from gaps that could allow fire and smoke to penetrate. Where necessary, wider gaps can be filled with appropriate materials to ensure a secure and airtight seal.



Surface Treatment
The smooth surface of fire protection boards makes them ideal for painting or coating. A base primer is recommended if the surface is to be painted or varnished. Surface treatment enhances the appearance and durability of the fire protection boards. It also provides an additional layer of protection against environmental factors such as moisture and UV radiation. Dispersion-, resin-, or acrylic-based fillers, paints, and varnishes from typical commercial manufacturers can be used. For special applications, the panel surface may need to be impregnated with alkali-resistant products.

 

Quality Control and Repairs
Aestuver fire protection boards are CE marked, and their properties are listed in the relevant European Technical Assessment (ETA) certificates. Some surface imperfections or damages can be repaired with appropriate materials. Quality control is essential to ensure that the tunnel fire protection system meets the required standards and performs as expected. Regular inspections should be conducted to check for any defects or damages that could affect the performance of the system. Surface imperfections, such as holes, bubbles, and scratches, can be repaired with repair mortar.

 

Conclusion

Installing fire protection systems for tunnels is a meticulous process that requires adherence to standards, proper handling, and the use of specific tools. By following the guidelines outlined in this article, you can ensure a safe and effective installation that enhances the safety and integrity of tunnel structures. Proper installation of fire protection systems is essential to protect tunnels from fire hazards and ensure the safety of occupants and emergency responders. It also helps to preserve the structural integrity of the tunnel and minimize damage in the event of a fire.

For more detailed information, refer to the installation manual and consult with experts as needed. Stay safe and ensure your fire protection systems are installed to the highest standards.

 
 

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