Firestopping electrical systems

When electrical engineers review the location of

rated walls, they should consider the layout of their
equipment to avoid the need to firestop.
By Timothy E. Kuhlman, PE, RCDD, CH2M HILL, Portland, Ore.
04/01/2011

Firestopping may not be the first thing that comes to

mind for an electrical engineer designing a power system. Too often, the
solution to firestopping a bank of conduits is left to the architect or
contractor. This can lead to costly construction workarounds and delays in
getting a building occupancy permit. Ideally, the electrical engineer will be
working with the architect to understand where the rated assemblies
(walls and floors) are in a building and designing their power system with
those assemblies in mind. This consideration taken into account early in
the design can save a lot of construction cost and angst at the end of the
project.
When electrical engineers review the location of rated walls, they should
consider the layout of their equipment to avoid the need to firestop. This
doesnt mean hiding penetrations. It means avoiding the penetration of
the rated walls in the first place. Figures 1 and 2 showing a rated partition
wall separating a transformer and panel board. Because the conduit does
not penetrate the rated partition, no firestopping is required.

Although Figures 1 and 2 illustrate the simplest of electrical systems,

there are some fundamental points that can be extrapolated and applied
to a more complex power design. The best way to ensure a rated
assembly, such as a wall, maintains its fire rating integrity is to not
penetrate the wall. A firestopping system that would be required (in Figure
1) has to be specified, installed, and maintained. All, if not done properly,
can compromise the walls integrity. The design in Figure 2 will require
additional effort by the electrical designer for placement of the gear and
specifying the proper conduit and wire. On the other hand, the architect
didnt have to specify a firestop penetration and the contractor never had
to install it.

When avoiding the rated assembly is not practical or possible, a

firestopping system is required. Selecting a firestopping system for a
power system is slightly different than selecting a system for powerlimited systems such as data networks, fire alarms, and controls where
the cabling is commonly routed exposed (not in conduit or enclosed
wireway). There are less likely to be changes in the power system
distribution than in power-limited systems. The part of the power system
that is most likely to see changes in the life of a facility is from the panel
boards to the outlets or lighting. Even then, this amount of change is
considerably less than what is typically seen for network cabling.
Therefore, selecting a firestop system that allows for multiple entries is
not a priority consideration for a powered system.
To properly select a firestopping system, the power system designer
should discuss the rated assemblies and their construction with the
architect. The rating of the assembly, the construction materials being
used, and the thickness and spacing of structural supports can affect the
selection of the firestopping system. The designer also must understand
the codes that define the fire and smoke protection for a building. Each
authority having jurisdiction (AHJ) defines the codes applicable to their

jurisdiction. For this discussion we will be referencing the International

Building Code2009, Chapter 7, Fire and Smoke Protection Features.
Planning
If you cant avoid penetrating a rated wall, then you better plan for it.
When planning for a wall penetration you need to understand three
things: the rating of wall, how the wall is constructed, and the materials
that will be penetrating it. The architect can tell you the wall rating and its
construction. Common materials for a fire-rated wall type include layers of
gypsum board, concrete, or concrete blocks. Common electrical system
components likely to penetrate a wall include conduit, busduct, cable tray,
and cable. Concrete and masonry walls require early coordination of the
exact size and location of openings where reinforcing is necessary.
Timing, flexibility, and access are also considered while planning the
penetrations. Depending on the design and construction schedule, the
rated wall type may be decided long before the electrical gear is selected
and its distribution determined. This could be due to a fast-track project
approach or long-term phasing of the project. When planning a
penetration in a concrete or block wall, a certain amount of flexibility may
be required depending on the size of a cable tray or manufacturer of a
busduct. Making a penetration larger in this type of wall after its built can
be a problem. Not all rated walls have access to both sides of the wall.
This may require the selection of a penetration method that can be sealed
with one-sided access.
Conduit
Table 1 shows a list of common electrical penetrations along with a list of
typical firestopping types. Lets consider the firestopping for a single
conduit penetration. This is probably the simplest and most common type
of electrical penetration. For a gypsum-board constructed, 2-hour rated
wall, the common firestop system will be either caulk or composite sheet.
As the penetrating hole and annular space get larger, more firestop
material and structure are required to hold the firestop material in place.

For example, Figures 3 and 4 show that a single 4-in. conduit making a 5in. penetration through a rated gypsum wall can be sealed using only
caulking. This type of system is good for a gap between the conduit and
penetration that is 2 in. or smaller. If the penetration gap is larger than 2
in., an approved backing material is needed to hold the caulk in place.
The use of a 28-gauge metal sleeve in the penetration and packing
material consisting of mineral wool insulation allows the annulus gap to
be up to 3 in. The firestop caulk type is the same for both penetrations,
but the larger annulus space around the conduit requires additional
firestopping structure. For firestopping holes with an annulus greater than
3 in., a composite sheet material can be used.

The composite sheet is secured to the wall and is cut to close the annular
space around the conduit penetration. The size of the penetration in the
rated wall is limited to the system requirements of the composite sheet.
For a gypsum stud wall, the composite sheet requires additional
horizontal bracing in the wall to secure the top and the bottom seam. The
composite sheet is often used in conjunction with a firestop sealant. Per
Underwriters Laboratories (UL) system requirements, the fire sealant is
used at the seams and around the gap or interface between the conduit
penetration and the composite sheet.

Cable tray
As shown in Table 1, the available firestop systems for cable tray differ
from those for conduit in that cable tray allows for the use of firestopping
pillows. There are systems that use caulk to firestop a cable tray
penetration; the caulk is used in conjunction with a mineral wool
insulation. In the example in Figure 5, the penetration using caulk allows
for a maximum cable cross-sectional area of 38% of the cable tray crosssectional area to be used for loading depth.
Although the use of caulk is possible, it is not very flexible. More common
are firestop pillows or composite sheeting used with cable tray
penetrations. Figure 5 shows the same type of cable tray being
firestopped with pillows. Re-entry of the firestop system using pillows is
slightly easier because there isnt as much caulk to be removed. For this
system, some caulk is still used to seal around the voids and gaps that
dont seal around the cables. This system allows for a maximum cable
cross-sectional area of 30% of the cable tray cross-sectional area to be
used for loading depth.

Of the three choices, the composite sheet provides for the neatest
installation while maintaining the integrity of the firestop. There arent any
pillows that can be knocked out or vibrate out of position. This assembly
may require a little more labor to fasten the composite sheet in the
penetration and to trim the sheet to the profile of the cable in the tray. Its
not as easy to re-enter if cables are added, as the composite sheet will
have to be removed to trim it to the new cable profile. However, a neat
installation provides for a clear visual inspection of the assembly to see if
it has been violated.
Busway and cablebus
Busways, also referred to as bus ducts, can be firestopped using any of
the three types of penetration sealants shown in Table 1. Smaller busway
assemblies can be firestopped with just the use of a firestop sealant.
Larger busway constructions may require the use of packing material in
conjunction with the sealant to fill the annular voids. In addition, a
manufacturers wall plate bulkhead may have to be provided to make the
system work as intended by the UL system requirements.
Firestopping pillows and composite sheet can be used with busways.
Either the pillows are packed around the busway or the composite sheet
is cut to fit the shape of the busway. In both applications, a small amount
of sealant is required to fill any voids around the busway. Unlike cable
tray, the firestop system does not impose a fill percent limitation on the
busway. The bus bars are completely contained on the inside of the
busway, and the firestop material is applied to the outside of the busway
enclosure. It is important to work with the manufacturer of the busway

product to specify the correct type of busway segment that will pass
through the rated wall.
Cablebus is a unique power distribution method consisting of an
enclosure that is similar to a ventilated cable tray system with a cover,
insulated conductors, and cable separators. The cablebus is
manufactured with cable support blocks to maintain separation between
the conductors to take advantage of the free air rating of the conductors.
Unlike busway, where a solid enclosure is provided by the manufacturer
to penetrate walls assemblies, the cablebus system maintains its open
ventilation. A cablebus penetration will require firestop components inside
the cablebus enclosure in addition to firestop sealant on the outside of the
cablebus. In laying out the cablebus system to be manufactured, the
electrical engineer needs to provide the cablebus manufacturer with the
specific location and the rating of the rated assemblies the cablebus will
be passing through. While the power distribution methods using conduit
and cable tray allow for a selection of firestopping methods, the firestop
for cablebus is integral to the cable and cablebus manufacturer.
Special areas and special assemblies
Special areas require special assemblies. The firestopping systems
considered up to this point are primarily intended to stop fire and smoke.
In some industrial environments, the assembly may also have to serve as
a seal against liquids or vapors, or be exposed to hazardous materials.
This requires a unique type of firestopping product. These specialty
products consist of a frame with block inserts. The block inserts come in a
variety of sizes to adapt to a range of diameters for conduit or cable
penetrations. Each block is made of concentric laminations that can be
removed in small increments to allow for a tight seal around a conduit or
cable. When cable or conduits are fully assembled in the penetration
frame, a compression block is used to lock the sealing blocks in place.

There are some trade-offs in specifying this type of assembly. The

laminated block firestop typically doesnt allow for the same number of
cables to pass through the same size of wall penetration as the more
traditional firestop materials previously noted. When penetrating concrete
floors or walls, the engineer needs to plan the size of the opening so that
the firestopping mounting frame can be either cast or bolted into place
afterward. However, this type of firestop is designed for a more
challenging environment. In addition, it provides flexibility to add or delete
cables in the penetration after the initial installation.

For example, in the case of a microelectronic manufacturing environment,

the manufacturing tools will be increased or swapped out as the factory
ramps up in yield. The microelectronics environment, an H5 occupancy,
may require a firestopping assembly for the power conductors connected
to the manufacturing tools coming from the power distribution panels
supplied from outside of the fabrication area. Microelectronic
manufacturing plants use a variety of hazardous production materials to
which the firestop could be exposed.
The specialty firestop block inserts can be opened to allow new cables to
pass through, or blocks can be added to seal unused openings. This can
be done without disturbing the other cables and doesnt require the reapplication of caulk, trimming of composite sheet, or replacement of

pillows. This system is designed for ease of assembly and disassembly. A

system like this that is designed for easy re-entry is less likely to be
compromised and therefore more likely to maintain its firestop and sealing
integrity.
Unused penetrations
For a variety of reasons, it will be necessary to seal off a penetration
through a rated wall that does not have a power conductor going through
it. This might be a penetration that is made for equipment that hasnt been
installed yet or for equipment that has been relocated. Regardless of the
reason, if there is an unused penetration in a rated wall, then it will need
to be repaired or firestopped. Smaller holes in a rated wall may be sealed
with a firestop sealant or putty. UL system requirements apply to unused
penetrations (holes) just as they apply to penetrating items. Depending on
the firestop caulk or putty used, the UL system application description will
prescribe the size of the hole that can be sealed. For caulking-type
firestopping the limit is approximately 2 in. in diameter or less, depending
on the manufacturer.
Larger penetrations can be sealed with pillows or composite sheet
materials. As with caulking, the UL system will prescribe the maximum
size penetration that can be sealed. This is usually given in a maximum
square inch area and the maximum length for one side of the penetration.
Unused penetrations that are larger than the maximum allowable
diameter to which the firestopping products can be applied will require the
reconstruction of the rated wall to re-establish the walls rated integrity.
Other considerations
So far we have considered how to firestop a rated wall for the power
system penetrating it. The selection of the firestop product may affect
cable tray fill, and might also affect the de-rating of the conductors
passing through it. Depending on the firestop system selected, the length
of the cable tray, conduit, or conductor path may be insulated by the
firestop system. This, in turn, can cause a hot spot in the conductor path.
For example, conductors in a cable tray passing through a composite
sheet used for firestopping have a limited contact area with the
firestopping system. A penetration using firestopping pillows may have a
6-in. length of conductors and cable tray that is insulated by the pillows. In
most applications, the requirements of NEC 310.15 and Annex B will
define the ampacity of the cable. IEEE Std 666-2007, IEEE Design Guide

for Electric Power Service Systems for Generating Stations, offers

considerations for ampacity adjustment when the firestopping method
causes a thermal gradient in the cable or other thermal change to the
raceway.
Another complicated issue for firestopping a conduit is where there are
back-to-back rated walls that can move independently. This can occur in a
rated firewall partition located between two structures separated by an
expansion joint or a structural isolation break. The designer must
understand the amount of building movement, evaluate the support
system, and then select the firestop system to that will work. Once again,
this provides an opportunity to coordinate with the firestop manufacturer
and the architect to find a workable solution.
Coordinating with the architect
The firestop construction specification is typically owned by the project
architect. It is necessary to work with the architect to understand the rated
assemblies throughout the facility. They will be key in providing a
consistent firestop solution for each rated assembly. The design process
between the architect and electrical engineer may be iterative as there
are limits to the total amount of penetrations that can be made or grouped
in a rated assembly and there are limits to the configuration of the power
system distribution.
When an existing firestop system cannot be prescribed for a penetration,
the architect may look for alternative means and methods to satisfy the
intent of the building code, AHJ, or insurance carrier. This may extend
beyond the specification of a firestop system and include other fire
protection means such as sprinklers, early warning smoke detection, and
compartmentalization of the space concerned.
An architect may also work with a firestopping manufacturer to develop
an engineered solution. Firestop systems are specific to the rated
assembly construction, the materials that are passing through them, and
firestop materials. If any of these components are outside of the
parameters of the UL system description, then that UL system cannot be
applied. The firestop manufacturer may do its own testing to provide data
showing that the engineered solution is viable. The architect can submit
this information to the approving bodies for compliance.

Commercial facilities most likely will use a wide variety of firestopping

systems that have already been tested and cataloged with a UL system
number. However, coordination with the architect is still necessary to
avoid delays in construction and building occupancy. In industrial facilities
where the power systems are much larger and more complicated, and the
environment is likely to be hazardous, using off-the-shelf solutions for
firestopping becomes more difficult. The development of building code
alternative means and methods or working with a manufacturer for an
engineered firestop solution takes time and planning.
Kuhlman has 24 years of experience in the design and construction of
telecommunications infrastructure. He is a member ofConsultingSpecifying Engineer's Editorial Advisory Board.