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EMSHIELD DFR2
UL 2079 Testing and Certification

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UL System FF-D-0075
Deck to Deck
1 to 2 inch (25 - 50mm)

UL System FF-D-1086
Deck to Deck
2.25  to 4 inch (55 - 100mm)

UL System FW-D-0052
Deck to Wall
1  to 2 inch (25 - 50mm)

UL System FW-D-1073
Deck to Wall
2.25  to 4 inch (55 - 100mm)

ULC System JF130

Underwriters Laboratories UL Certification
ULC Certification

Manufacture: UL certification begins with certification of the manufacturing process.  UL personnel observe the entire manufacturing process from impregnation to coating to packaging.

Installation: Next, an installation to include a join between standard lengths, using the tools, and procedures that will be used in the field is observed by UL.  Specifically, 4-inch nominal DFR2 was installed into 4-inch thick concrete slabs (4-inches of concrete are required for the concrete itself to provide 2-hours of fire resistance).  Once the epoxy-adhesive and liquid sealants used in the installation were cured, the slabs were ready for cycling.

EMSHIELD DFR2 was tested both with just the intumescent bellows on the bottom  side (standard offering to allow visual inspection verification of presence of fire proofing), as well as with the intumescent bellows on the bottom side coated with a silicone bellows (optional at additional charge to suit designers aesthetic preference).

Joint Cycling:  Before any fire testing can commence, the product must pass UL's cycling requirement through the extremes of the offered movement range (+25%, -25% from nominal). 

Joint movement under UL 2079 occurs at two levels.  The first, 400 cycles @ 10 cycles/minute simulates thermal and wind-sway cycling.  The second, an additional 100 cycles @ 30 cycles per minute, is more rapid and is designed to simulate seismic movement. EMSHIELD DFR2 passed cycling for both Class II and Class III movement capabilities.

Fire Resistance:  Within 96 hours of the cycling tests the fire testing must occur.  The concrete slabs with installed expansion joint material are placed over the test oven. 

The joint gap is set at the maximum offered opening for the material size tested (4-inch nominal material at +25% movement claim = 5-inches).

Thermo couples are placed on the top side of the material.  (When fire-blankets are tested, because they cannot support traffic of any kind, they are tested with a plate or other joint cover across the joint gap onto which the thermo couples are set.)

For the DFR2, the thermo couples were placed directly on the trafficable exposed upper surface of the material--in the middle of the product, at the substrate interface, and directly over the field-join.

The oven is ignited and the temperature rises rapidly to near 1650^oF (899^oC) in about 30 minutes. After two hours the internal temperature of the oven reaches 1850^oF (1010^oC).

The data from the thermo couples is monitored throughout the 2 hour duration of the test.

To pass, no single thermo couple can read in excess of 356^oF (180^oC) at any point during the duration of the test.

After two hours, no single thermo couple on the EMSHIELD DFR2 read in excess of 248^oF (120^oC).  (The noticeable bow in the concrete slabs is evidence of the differential expansion of the heated concrete on the fire-side of the slabs.)

The successful conclusion of the test earns the EMSHIELD DFR2 the certification by UL of this product in sizes from 4-inches and smaller at depths of 4-inches and with a movement capability of +25% and -25% (total 50%) to be fire-rated for up to 2 hours.

Underwriters Laboratories UL Certification
ULC Certification

 

Traffic Durable, Watertight, 2-Hour Rated Expansion Joint

EMSHIELD DFR2 is a watertight, fire-rated, traffic-durable primary seal for both retrofit and new structural expansion joints in horizontal-plane applications.

EMSHIELD DFR2 eliminates the need for additional fire blankets, mineral wools, liquid sealants, cover plates, or other fire stopping materials.

For joints from 1 to 4-inches (25-100mm) where +25% and -25% (total 50%) of nominal material size joint movement is expected.

EMSHIELD DFR2 (Deck, Fire-Rated 2-Hours) builds on EMSEAL's track record of over 30 years of innovation in sealing structural expansion joints with impregnated foam sealants and is the first in a comprehensive line of breakthrough, multi-function, structural expansion joint materials being released by EMSEAL. Tested and certified by Underwriters Laboratories (UL), to the rigors of UL 2079, additional versions for walls and floors are expected to be made available shortly--consult EMSEAL.

Fire-retardant-impregnated foam is factory pre-coated on the underside with an intumescent fire-proofing material. The traffic surface receives a traffic-grade silicone coating.  The resulting composite is then factory compressed to less than its nominal size for installation into structural or other openings. 

NEW! EMSHIELD WFR2 (Wall Fire-Rated 2-Hours) for wall and vertical rise applications is now available. It can be combined with EMSHIELD DFR2 to create a completely fire-rated horizontal and vertical system.

EMSHIELD DFR2 provides a watertight, clean handling, UV stable, non-staining, low-temperature-flexible, high-temperature-stable, watertight, traffic durable and fire-rated joint seal in a single installation process.

Uses For expansion joints in decks and floors where watertightness and/or a fire-rating and/or traffic durability are required.  Applications examples are:

• Stadiums • Arenas • Parking Decks • Floors • Stair Tower Perimeters • Elevator Tower Perimeters • Deck-to-Deck • Deck-To-Wall • Bridge Expansion Joints • Interior Floors Under Joint Covers Can be used alone or under any other expansion joint cover, plate or filler where depth of substrate allows.

Product Description EMSHIELD DFR2 features a traffic-grade silicone sealing surface adhered to a fire-retardant impregnated foam backing and an intumescent bellows on the bottom (fire) side.

The system is installed into epoxy adhesive field-applied to the sides of the foam and on the joint faces.  A field-injected silicone sealant band seals the bellows to the substrate. (Note: A sealant band of intumescent caulk from the underside is NOT REQUIRED enabling the installation to be done entirely from the top side).  Joins between each stick are executed using a field-applied silicone sealant band at the top of the join and an intumescent sealant coating over the remaining foam at the adjoining faces.

Figure 1: EMSHIELD DFR2 in Typical Deck-To-Deck Installation

Figure 2: EMSHIELD DFR2 in Typical Deck-To-Wall Installation

Features Watertight — EMSHIELD DFR2 is installed with the tensionless traffic-grade, fuel-resistant bellows facing the traffic ensuring that watertightness is achieved. Fire-Rated — The fire-retardant-impregnated foam and intumescent bellows is installed facing the lower floor ensuring 2-hour fire protection in accordance with UL-2079. Non-Invasive Anchoring — There are no hard metal-to-substrate connections with EMSHIELD DFR2. This includes embedded pins, anchors, screws, bolts or tracks, trays or rails, flanges or coverplates. The system is locked to the joint faces by means of the 1) backpressure of the foam; 2) the epoxy adhesive, and 3) the injected sealant bands at the joint face. Versatility — The standard EMSHIELD DFR2 top surface color is gray (other colors are optional). The standard underside color is "intumescent-red".  This provides a visual inspection cue to ensure the presence of the fire-proofing.  At the designer's option, an additional silicone color coating can be applied to the underside. Joint-Size Variation —Uniform bellows appearance, and the ability to handle variations in joint size through size-switching. Sound Attenuation -- Floors sealed with EMSEAL impregnated foam sealants offer exceptional acoustic dampening and feature sound transmission coefficients virtually equal to that of the solid slab.

Factory-Fabricated Terminations and Transitions— as in all EMSEAL expansion joint systems, continuity of seal through changes in plane and direction is an essential performance differentiator. EMSHIELD DFR2 is manufactured in straight-run sticks which can be joined in the field to EMSEAL’s patent-pending DFR2 "Universal-90" Transitions and Terminations. Universal-90 Upturn Termination Universal-90 Flipped-Over as Downturn Termination Universal-90 Upturn Transition Universal-90 Flipped-Over as Downturn Transition These factory-fabricated single-piece 90-degree units have a 12-inch long leg and a 6-inch vertical piece on each end of the elbow.   The Universal-90's are symmetrically coated on both sides.  This allows them to be installed as an upturn or as a downturn.  Either leg can be trimmed in the field to connect to straight run material or to another Universal-90 when going, for example, up and over a curb, into a parapet, or up and down treads and risers. Universal-90 terminations end, on the 6-inch leg, in a 45o sealed and mitered end.  This allows termination as a stand alone upturn or provides a surface against to which a wall joint system can be married.  Flipped over, the Universal-90 termination unit can be alternatively installed as downturn termination where a joint runs off the deck.  In this use, the sealed, mitered end provides a drip edge for drainage of water off the joint. In addition to guaranteeing a continuous waterproof coating, EMSEAL’s "Universal-90's" allow for much faster and secure installation by eliminating field cutting or notching and bending at angles.

Performance Sizing Movement Capability: +25%, -25% (50% total) of nominal material size. Standard sizes from: 1" to 4" (25-100mm) Depth of Seal for all sizes: 4" (100mm).  Note: Thickness of concrete for 2-hour rating = 4" (100mm). Substrates must be solid, parallel and plumb. Supplied Product  Nominal Material Size Depth of Length Code ( = Joint Size at Mean T) Seal 6.56 LF (2M)  DFR2-100-100-02 1"  (25mm) 4" (100mm) Stick DFR2-125-100-02 1 1/4" (30mm) 4" (100mm) DFR2-150-100-02 1 1/2" (40mm) 4" (100mm) DFR2-175-100-02 1 3/4" (45mm) 4" (100mm) DFR2-200-100-02 2" (50mm) 4" (100mm) DFR2-225-100-02 2 1/4" (55mm) 4" (100mm) DFR2-250-100-02 2 1/2" (60mm) 4" (100mm) DFR2-275-100-02 2 3/4" (70mm) 4" (100mm) DFR2-300-100-02 3" (75mm) 4" (100mm) DFR2-325-100-02 3 1/4" (80mm) 4" (100mm) DFR2-350-100-02 3 1/2" (90mm) 4" (100mm) DFR2-375-100-02 3 3/4" (95mm) 4" (100mm) DFR2-400-100-02 4" (100mm) 4" (100mm)

Colors Standard traffic surface color is gray (consult EMSEAL for options). Standard underside color is 'intumescent red' to facilitate visual inspection of presence of fire proofing.  Additional color coating on bottom side is available as an option--consult EMSEAL.

Testing and Standards EMSHIELD DFR2 has been tested and certified under UL 2079. EMSHIELD DFR2 meets the requirements of ASTM E1966, ASTM E119 and ASTM E1399. UL 2079, like ASTM E1966, was developed to encompass the fire testing of ASTM E119 and the movement cycling regime of ASTM E1399. EMSEAL’s EMSHIELD DFR2 has been tested in accordance with UL 2079 in the configuration depicted in UL Systems: # FF-D-0075, # FF-D-1086, # FW-D-0052, # FW-D-1073. Use of this material in deck assembly configurations other than depicted in these named UL certified systems will not encumber or lower the resistance of the deck but is done so at the designers’ discretion and responsibility for design of a fire rated deck assembly that meets applicable standards for the project. FIRE RATING Expansion Joints in BRIDGE Design: With notable events such as Oakland California's tanker-fire fed structural collapse of the MacArthur Maze Freeway interchange roadway spans, fire-rating of bridge structures is being increasingly considered.  Extension of fire rated design across expansion joints can be achieved with EMSEAL's breakthrough fire-rated, traffic durable, high movement and watertight joint seal.  EMSHIELD DFR2 provides all of these functions in a single product installation.  Movement cycled and 2-hour fire tested to UL 2079, EMSHIELD DFR2 is the first of its kind expansion joint system to satisfy all performance demands in a single installation process.   EMSHIELD DFR2 References / EMSEAL BLOG Click to learn more... ◊ Berlin Federal Prison

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