Tunnel Application

Click on any of the pictures below to see the various application systems we have designed to meet the requirements of Bored Tube, Cut & Cover, and Immersed Tube Tunnels.

Click on any of the red process labels to get more details on how our fire protection systems are applied to Bored Tube, Cut & Cover, and Immersed Tube Tunnels.

< BACK

Prepared Surface

Prepared Surface

Ensure that the concrete substrate is completely clean and free from contaminants such as curing compounds and mould release agents prior to the application and installation of the CAFCO® FENDOLITE® M-II System. For heavily contaminated substrates, this may be accomplished by pressure washing the entire concrete surface with a minimum 3000 psi pressure washer.

Keycoat

Keycoat

Prior to the installation of the reinforcement system, mix and spray apply the ISOLATEK® SBR / CAFCO® FENDOLITE® M-II keycoat at a coverage rate of 20 % to 50 % of the surface area and allow this to cure and dry.

Mesh Retention System with anchors

Mesh Retention System with anchors

Install 50mm x 50mm x 1.6mm plastic coated galvanized hexagonal mesh or 50mm x 50mm x 1.6mm stainless steel profiled mesh using approved stainless steel anchors at approximately 400mm spacing on a staggered pitch.

Pull Away Mesh

Pull Away Mesh

Plastic coated mesh should be pulled away from the concrete surface to lie substantially within the mid-third of the total CAFCO® FENDOLITE® M-II thickness.

CAFCO® FENDOLITE® M-II

CAFCO® FENDOLITE® M-II

The CAFCO® FENDOLITE® M-II should be spray applied in the minimum number of coats to achieve a final thickness. The Type M-II may be left with either a spray textured finish or be troweled smooth where topcoat paint systems are to be applied.

Light Reflectant / Washable Topcoat

Light Reflectant / Washable Topcoat

After CAFCO® FENDOLITE® M-II has cured and dried, a light reflectant topcoat may be applied in a minimum of two coats to provide the specified light reflectancy. The first coat should penetrate into the CAFCO® FENDOLITE® M-II surface to create sufficient bond.

< BACK

Prepared Surface

Prepared Surface

Ensure that the concrete substrate is completely clean and free from contaminants such as curing compounds and mould release agents prior to the application and installation of the CAFCO® FENDOLITE® M-II System. For heavily contaminated substrates, this may be accomplished by pressure washing the entire concrete surface with a minimum 3000 psi pressure washer.

Keycoat

Keycoat

Prior to the installation of the reinforcement system, mix and spray apply the ISOLATEK® SBR / CAFCO® FENDOLITE® M-II keycoat at a coverage rate of 20 % to 50 % of the surface area and allow this to cure and dry.

Mesh Retention System with anchors

Mesh Retention System with anchors

Install 50mm x 50mm x 1.6mm plastic coated galvanized hexagonal mesh using approved stainless steel anchors at approximately 400mm spacing on a staggered pitch.

Pull Away Mesh

Pull Away Mesh

Plastic coated mesh should be pulled away from the concrete surface to lie substantially within the mid-third of the total CAFCO® FENDOLITE® M-II thickness.

CAFCO® FENDOLITE® M-II

CAFCO® FENDOLITE® M-II

The CAFCO® FENDOLITE® M-II should be spray applied in the minimum number of coats to achieve a final thickness. The Type M-II may be left with either a spray textured finish or be troweled smooth where topcoat paint systems are to be applied.

Light Reflectant / Washable Topcoat

Light Reflectant / Washable Topcoat

After CAFCO® FENDOLITE® M-II has cured and dried, a light reflectant topcoat may be applied in a minimum of two coats to provide the specified light reflectancy. The first coat should penetrate into the CAFCO® FENDOLITE® M-II surface to create sufficient bond.

< BACK

Prepared
Surface

Prepared Surface

Ensure that the concrete substrate is completely clean and free from contaminants such as curing compounds and mould release agents prior to the application and installation of the CAFCO® FENDOLITE® M-II System. For heavily contaminated substrates, this may be accomplished by pressure washing the entire concrete surface with a minimum 3000 psi pressure washer.

Keycoat

Keycoat

Prior to the installation of the reinforcement system, mix and spray apply the ISOLATEK® SBR / CAFCO® FENDOLITE® M-II keycoat at a coverage rate of 20 % to 50 % of the surface area and allow this to cure and dry.

Mesh Retention System with anchors

Mesh Retention System with anchors

Install 50mm x 50mm x 1.6mm plastic coated galvanized hexagonal mesh or 50mm x 50mm x 1.6mm stainless steel profiled mesh using approved stainless steel anchors at approximately 400mm spacing on a staggered pitch.

Pull Away Mesh

Pull Away Mesh

Plastic coated mesh should be pulled away from the concrete surface to lie substantially within the mid-third of the total CAFCO® FENDOLITE® M-II thickness.

CAFCO® FENDOLITE® M-II

CAFCO® FENDOLITE® M-II

The CAFCO® FENDOLITE® M-II should be spray applied in the minimum number of coats to achieve a final thickness. The Type M-II may be left with either a spray textured finish or be troweled smooth where topcoat paint systems are to be applied.

Light Reflectant / Washable Topcoat

Light Reflectant / Washable Topcoat

After CAFCO® FENDOLITE® M-II has cured and dried, a light reflectant topcoat may be applied in a minimum of two coats to provide the specified light reflectancy. The first coat should penetrate into the CAFCO® FENDOLITE® M-II surface to create sufficient bond.

< BACK

Unistrut Framing System

Unistrut Framing System

The Unistrut framing system shall be constructed in accordance with the manufacturers recommendations to suit the specific tunnel profile. A framing system should be fixed to the primary lining using suitable anchors as reccomended by the manufacturer. For location and fixing of the mesh retention system, suitable Capacitor Discharge (CD) welded pins to be attached to the unistrut prior to the application of CAFCO® FENDOLITE® Type M-II or the optional impervious basecoat.

Riblath

Riblath

Fix the riblath to the Unistrut framework and secure to the previously installed CD pins and secure using non-return washers.

Impervious Basecoat (optional)

Impervious Basecoat (optional)

If water ingress through the primary tunnel lining is to be managed, ISOLATEK® Impervious Basecoat may be spray-applied to the riblath at a thickness of 10mm, proud of lath.

Mesh Retention System with anchors

Mesh Retention System with anchors

Install 50mm x 50mm x 1.6mm plastic coated galvanized hexagonal mesh to the previously installed CD weld pins and secure using non-return washers.

Pull Away Mesh

Pull Away Mesh

Plastic coated mesh should be pulled away from the surface of the lath or optional impervious basecoat to lie substantially within the mid-third of the total CAFCO® FENDOLITE® M-II thickness.

CAFCO® FENDOLITE® M-II

CAFCO® FENDOLITE® M-II

The CAFCO® FENDOLITE® M-II should be spray applied in the minimum number of coats to achieve a final thickness. The Type M-II may be left with either a spray textured finish or be troweled smooth where topcoat paint systems are to be applied.

Light Reflectant / Washable Topcoat

Light Reflectant / Washable Topcoat

After CAFCO® FENDOLITE® M-II has cured and dried, a light reflectant topcoat may be applied in a minimum of two coats to provide the specified light reflectancy. The first coat should penetrate into the CAFCO® FENDOLITE® M-II surface to create sufficient bond.

Bored Tunnel

Immersed Tube

The animations contained herein are not intended to replace a thorough understanding of Isolatek application guidelines. For further information on all application methods contact Isolatek International or one of our business partners.

Bored Tunnels

Bored tunnels are constructed using Tunnel Boring Machines (TBM’s) that cut through strata using a circular cutting head, removing the excavated material behind it. The TBM then places pre-cast, high strength concrete segments in a circular “ring” to form a primary tunnel lining. In these types of tunnels, the CAFCO® FENDOLITE® M-II system is applied to the tunnel segments to prevent spalling under fire exposure conditions.

Cut & Cover Tunnels

Cut and Cover tunnels are constructed using a number of established techniques including:

  • Conventional construction methods
  • Bottom-up construction
  • Top-Down construction
  • Cast-in-Place construction

In these types of tunnels, the CAFCO FENDOLITE M-II system is normally applied to the tunnel soffits and partially down the supporting walls in order to prevent collapse of the structure under fire exposure conditions.

Immersed Tunnels

Immersed Tube Tunnels are constructed by casting tunnel elements in dry-docks and floating them to their final location. The elements are then sunk into pre-formed trenches on the sea bed and connected to each other. The immersion joints between the elements are sealed using “Gina” and “Omega” gaskets that are a critical part of the construction. In these types of tunnels, the CAFCO FENDOLITE M-II system is applied to the soffits and external walls and partially down the internal supporting walls to prevent collapse of the structure under fire exposure conditions. Specific solutions, based on the CAFCO FENDOLITE M-II system can also be developed for the fire protection of the immersion joints.

”CAFCO FENDOLITE TG is mixed
then hand applied using common masonry tools.”

In order to obtain optimal results, the following spray equipment setup for CAFCO® FENDOLITE® M-II on
Industrial, Chemical and Petrochemical processing sites is required:

  • A rotor stator type, open throat, screw feed pump with minimum “No. 4” soft rubber stators.
  • Compressed air is required and must be delivered to the spray nozzle at a minimum volume of 15 cfm
    (420 L/min) and a minimum pressure of 50 psi (3.51 kg/cm²).
  • A paddle or ribbon-type mortar mixer with a safety cover, rubber tipped blades and provision for quick dumping of mix directly into the pump hopper is recommended. Mixers with an 8 cu. ft. (227 liters) capacity or larger, capable of operating speeds of 35 to 40 RPM.
  • Screw-on type quick connect/disconnect couplings that do not restrict product flow are required
  • The spray nozzle assembly must consist of a minimum 1 in. (25 mm) ID aluminum pole with a blow-off type nozzle cap, a nozzle orifice and valves for product and air control. Nozzle orifice must be nominal 1/2 in. diameter (13 mm).

CAFCO® FENDOLITE® TG is mixed and then hand applied using common masonry tools.

Galvanized Mesh

Galvanized Mesh

Plastic Coated Galvanized Hexagonal Mesh.

View Suppliers >

Suppliers
ISOLATEK INTERNATIONAL
41 Furnace Street
Stanhope NJ 07874, USA
Tel: 1-800-631-9600
isolatek.com

Galvanized Mesh

Stainless Steel Mesh

Grade 316 Stainless steel welded wire mesh

View Suppliers >

Suppliers
ISOLATEK INTERNATIONAL
41 Furnace Street
Stanhope NJ 07874, USA
Tel: 1-800-631-9600
isolatek.com

Stainless Steel Pins

Stainless Steel Anchors

Grade 316. Stainless steel mesh reinforcement pins

View Suppliers >

Stainless Steel Pins Suppliers
ISOLATEK INTERNATIONAL
41 Furnace Street
Stanhope NJ 07874, USA
Tel: 1-800-631-9600
isolatek.com

spraymate60-thumb

Sprayer Equipment

Rotor stator type with open throat and screw feed.

View Manufacturers >

Spray-Equipment Manufacturers
Mayco/Essicks
18910 Wilmington Avenue
Carson, CA 90746, USA
Tel: 800-421-1244
FM9 #4 Rotor-Stator Pump (discontinued)
Mixer, EM90SH8, EM90PH8 (plastic drum)
8 cu. ft. (225 liters) paddle & ribbon mixers
Thomsen/ Putzmeister-United States
18620 So. Broadway
Gardena, CA 90248, USA
Tel: 213-321-8380
putzmeister.com
putzmeisteramerica.com
S5-EV (electric), S5-GH (gas)
Putzmeister-United Kingdom
Putzmeister Ltd.
Chesterfield Trading Estate
Carrwood Road
S41 9QB
Chesterfield Derbyshire
United Kingdom
+44 (0) 1246-264200
Putzmeister.co.uk
SP-11
Spray-King Mfg. Inc.
3535 North Duke Avenue
Fresno, CA 93727, USA
Tel: 800-448-5555 or 559-291-5586
spraykingmfg.com
#4, #6 rotor/stator pumps
Hydrolic Dump Over, P88 or D88, 200 HYD, 300 HYD,
TH14, Terminator Super 450
Strong Mfg.
P.O. Box 8068
Pine Bluff, AR 71611, USA
Tel: 800-238-5042 or 870-535-4753
strongmfg.com
#4, #6 rotor/stator pumps – Spraymate 60
Hyflex Corp.
8774 South State Road. 109
Knightstown, IN 46148 USA
Tel: 1 765-571-5125 or 1 866-849-6246
hyflexcorp.com
#4, #6 rotor/stator pumps
HZ-30E (electric), HZ-30G (gas), HZ-30DM (diesel)

View Distributors >

Spray-Equipment Distributors
The Donnelly Company
753 Rowley Road
Victor, New York 14564, USA
Tel: 800-624-3530 or 716-924-0640
Putzmeister, Mayco/Essicks, Hyflex, J&M Service Inc., Quickspray Inc., Stone Construction Equipment Inc., Construction Forms Inc.
Walker Equipment
3009 South Jackson Avenue
S. Chicago Heights, IL 60411, USA
Tel: 708-754-7070 or 800-227-7072
walker-equipment.com
Equipment rentals – Putzmeister (S5-EV or S5-GH)
Nathan Kimmel Company, LLC
1213 South Santa Fe Avenue
Los Angeles, CA 90021, USA
Tel: 800-431-0005 or 213-627-8556
nathankimmel.com
8 cu. ft. (225 liter) paddle & ribbon mixers
American Spray Technology, Hyflex, Multiquip, Putzmeister, QuickSpray Inc., Toro
Hardline Services Inc.
PO Box 2884
Fullerton CA 92837
717F S State College Blvd Fullerton CA. 92831

Tel: 657-217-0703
Tel: 657-217-5250
Cell: 714-357-8260
sales@hardlineservices.com

Putzmeister, Mayco, Graco, GFI pumps, BR Pumps, Neptune

Nozzles/ Guns - Fendolite fire damage protection

Nozzles/ Guns

Minimum 1” ID aluminum pole to provide minimum volume of 15 cfm (420 L / min).

View Suppliers >

Suppliers
The Donnelly Company
1753 Rowley Road
Victor, New York 14564, USA
Tel: 800-624-3530 or 716-924-0640
Walker Equipment
13009 South Jackson Avenue
S. Chicago Heights, IL 60411, USA
Tel: 708-754-7070 or 800-227-7072
walker-equipment.com
Nathan Kimmel Company, LLC
1213 South Santa Fe Avenue
Los Angeles, CA 90021, USA
Tel: 800-431-0005 or 213-627-8556
nathankimmel.com

Hoses/ Couplings/ Reducers - Fire prevention system

Hoses / Couplings / Reducers

High pressure grout hose for plaster, grout and cement applications. Screw-on type quick connect/disconnect couplings which do not restrict product flow reducers.

View Suppliers >

Suppliers >
The Donnelly Company
753 Rowley Road
Victor, NY 14564, USA
Tel: 800-624-3530 or 716-924-0640
Parts/accessories – Goodyear Hoses and fittings.
Miscellaneous equipment
Walker Equipment
3009 South Jackson Avenue
S. Chicago Heights, IL 60411, USA
Tel: 708-754-7070 or 800-227-7072
walker-equipment.com
Parts/accessories – Goodyear Hoses and fittings.
Miscellaneous equipment
Nathan Kimmel Company, LLC
1213 South Santa Fe Avenue
Los Angeles, CA 90021, USA
Tel: 800-431-0005 or 213-627-8556
nathankimmel.com

“Proper preparation of
substrates is important in providing adhesion and durability over time.”

Careful preparation of substrates is important. Correct preparation ensures that the durability of the fire protection system is maintained and the required level of adhesion is achieved. Poorly prepared substrates will compromise the long term protection to the structure. It is required that the substrates are prepared in accordance with Isolatek International’s written application instructions.

The substrate to be protected with the CAFCO® FENDOLITE® M-II system must be prepared such that it is free from dirt, dust, oil, curing compounds, mould release agents or other contamination that would impair the adhesion of CAFCO FENDOLITE M-II system. For heavily contaminated substrates, this may be accomplished by pressure washing the entire concrete surface with a minimum 3000 psi pressure washer.

For direct application to concrete surfaces, a CAFCO FENDOLITE M-II / ISOLATEK® SBR keycoat is applied to increase the surface area to be protected by CAFCO FENDOLITE M-II. The specified method of mesh retention (i.e. plastic coated galvanized or stainless steel profile mesh) may then be installed prior to the application of CAFCO FENDOLITE M-II.

For applications onto metal lath substrates, concrete surface cleaning and the application of an SBR keycoat is not normally required.

Refer to our Application Techniques section for more details regarding the step by step processes used.

”An Inspection program is essential to maintain the
integrity and long term durability of a completely
installed fireproofing system.”

Inspection and Repair Procedures of the CAFCO® FENDOLITE® M-II and
CAFCO® FENDOLITE® TG System for Tunnel Applications – Short Form

Routine annual inspections may be carried out on the Spray-Applied Fire Resistive Materials (SFRMs) to ensure that the product will continue to
perform its intended function.

Tunnel walls may be subjected to vehicle impact. As a result, any damage to the fire protection system can be easily repaired in accordance with Isolatek International’s application instructions.

An annual inspection program is recommended to ensure that the integrity of a completely installed fireproofing system is maintained.

This inspection survey must be conducted by qualified QA/QC personnel with knowledge of the fireproofing system, and recommended and approved by Isolatek International.

The procedures outlined below are intended as a guide for conducting your inspection program. The QA/QC personnel will need a complete copy of the as-built drawings of the system for mark up, along with access to the site. The inspection report and drawings are to remain with the owner and/or owner’s rep upon completion of survey.

1.0 INSPECTION

  • 1.1
    The QA/QC personnel will inspect and record on the drawings all areas of concern including but not limited to locations where:
    • Fireproofing system is damaged
    • Retention system is damaged
    • Previous repaired areas
    • Delamination areas
    • Cracking
    • Mildew
    • Chemical stain/damage areas
    • Wet areas
    • Top coat/sealer failure
    • Damaged joints and seals
  • 1.2
    The QA/QC personnel shall submit to the owner and/or owners representative all of the drawings with the mark ups, along
    with a written procedure to complete all of the necessary repairs of the fireproofing system in accordance with
    Isolatek® International’s guidelines.

2.0 RECOMMENDATIONS

  • 2.1
    QA/QC personnel must ascertain which observed items require attention within the current maintenance cycle, based on one or
    both of the following criteria:
    • A repair (i.e. fissure or crack) which may allow moisture and chemical ingress / accumulation behind the fireproofing material.
    • Aesthetic appeal.

3.0 REPAIR

  • 3.1
    Termination Seal Delamination and/or Cracking.
    1. Strip away the old damaged joint seals to reveal the original surfaces. The seals must be reinstated in accordance with the original specifications.
  • 3.2
    Topcoat Damage
    1. Remove all peeling topcoat by following the SSPC-SP 2 (hand tool cleaning) specification.
    2. Ensure surface is free from dust and other contaminants.
    3. Re-apply topcoat in accordance with original specifications.
  • 3.3
    Repair of the fire protection system
    1. Remove existing/damaged material.
    2. Reinstate all damaged components in accordance with the original specification.
    3. Pre-wet the existing CAFCO FENDOLITE fireproofing material.
    4. Apply CAFCO FENDOLITE M-II or TG into the repair area, taking care to push the material behind the reinforcement and completely filling any voids.
    5. Wait approximately 7 to 10 days before re-applying the approved topcoat (if necessary).

Should you have further questions pertaining to this matter, please contact the Isolatek International Technical Service Department at 800.631.9600, extension 269.

Quality Control Test Data Report (Form # C01A)

In order to provide a method for our customers to monitor and maintain product quality during installation, we have developed the Quality Control Test Data Report (Form # C01A). This method provides a record of quality data as the product is installed and allows means to address non-conformities. At the end of the project there is a record that the product and the installation have met all performance standards. This minimizes future risk and gives applicators, engineers and architects the highest degree of confidence in their fire resistive system.