Project: Mitchell House, Macon, Georgia

The Mitchell house was the home of Margaret Mitchell, author of Gone with the Wind. The building was converted to condominiums above the first floor. The ceiling in the first floor had embossed tin ceilings requiring a 1 hour rating. To comply would have required removal of the ceiling, application of 2 layers of gypsum board and re-installation of the ceiling.

Problem:
The first floor area was extensive and occupied by a fabric store that was opened daily. The cost of demolition and reconstruction, including potential damage to the existing ceiling tiles was extensive and would have required shutting down the store for a minimum of 4 weeks.

Solution:
Based on Firefree88 testing on embossed tin ceilings, we were approved and used to coat the embossed tin ceiling to provide the necessary 1 hour rating at a 60% reduction in cost. The labor was performed at night and completed in 7 work days with no disruption to the owner of the fabric store.


Project: Home of General Patton, Fort Bragg, North Carolina

Bring the home of General Patton up to current fire codes.

Problem:
The home was converted to a museum. Due to the age of the home and the interior materials used in the construction of the home, the building, now converted to a museum, did not meet current fire codes. To bring the home up to the current fire standards would have required removal of all moldings and rebuilding of walls and ceilings within the home. This was a costly, disruptive and time consuming process that exceeded the military budget for this project.

Solution:
Based on Firefree88 testing on lath and plaster and wood assemblies, we were able to simply apply the coating to the wall and ceiling areas to provide the necessary fire ratings required at a greatly reduced cost, with minimal disruption and less construction time than the alternative solution as stated above.


Project: Firefighters Museum, Georgia

The museum was required to meet new fire codes prior to opening. The ceiling, finished with embossed tin ceiling panels was required to meet a 1 hour rating. The job scope would have required removal of the entire ceiling, installation of 2 layers of gypsum board and re-installation of the tin ceiling.

Problem:
The floor area was extensive. The cost of demolition and reconstruction, including potential damage to the existing ceiling tiles was extensive and would have delayed the opening of the museum for a minimum of 6 to 8 weeks

Solution:
Based on Firefree88 testing on embossed tin ceilings, we were approved and used to coat the embossed tin ceiling to provide the necessary 1 hour rating at a 50% reduction in cost. The Project was completed in 5 working days.


Project: Honeywell Corporation

The Honeywell plant in Minnesota had over 100,000 square feet of ceiling that had a highly flammable cellulose board glued to the ceiling. The ceiling required a fire rating upgrade.

Problem:
The plant was in operation and the solution being considered was to remove all ceiling panels and re-install new material that would meet the required fire rating. The cost, time required and disruption to the plant would be extensive.

Solution:
Based on testing of the Firefree88 coating on the cellulose material, we were able to simply coat the ceiling at a greatly reduced cost (55%) with a greatly reduced time to complete the project with less disruption to the plant work force.


Project: General Dynamics Corporation

The General Dynamics office building in Santa Clara, CA was being remodeled with a large area of wood beams and plywood above a suspended ‘T’ bar ceiling that required a 1 hour fire rating.

Problem:
Since all HVAC, electrical conduit and other piping was in existing in the ceiling, it would require removal of all those items, installation of 2 layers of gypsum board and re-installation of all ducts and conduit. The cost to perform the repair was quite extensive.

Solution:
Based on the extensive testing on wood assemblies to 1 and 2 hour testing standards, the FF88 coating was applied to all wood ceiling areas to provide the required 1 hour rating at a savings of over 70% compared to the alternate solution. The work was completed in 8 work days.


Project: Hospice Care Facility, Columbus, Georgia

Upgrade an existing assisted living facility to a full care hospice facility.

Problem:
With the change in usage, the first to second floor ceilings needed to be upgraded to a 1 hour rating. The existing ceiling had one layer of 5.8” type “X” gypsum where a second layer was required to meet the 1 hour fire rating. The ceiling in the corridor areas had suspended ceilings with conduits installed above. The rooms off of the corridors were occupied with patients. The standard repair would have been to install a second layer of gypsum board. This would have been costly, complicated and extremely disruptive in the rooms with patients, requiring multiple days of disruption per room (4-5 days per room) while trying to accommodate the work. In the corridors, the suspended ceiling and electrical conduits and other wiring would have to be removed.

Solution:
Based on our extensive 1 & 2 hour testing on gypsum ceiling assemblies, the Ff88 coating was approved and used to provide the required fire ratings to the ceilings of the hall corridors and the rooms. Multiple patient rooms were able to be coated each day. The coating is non toxic, with a low VOC rating (33 grams per liter), fast drying with no odor which allowed the patients back into the rooms at the end of the work day. The savings in both cost and time was substantial.


Project: Hospice Care Facility, Valdosta, Georgia

Correct fire rating defects at the attic of the facility.

Problem:
The building had major fire defect issues in the entire attic space of the Facility including the inability to get sprinklers in the attic space and not being able to install fire dampers in the attic. The method of repair considered was to remove all ceiling sheet rock, ceiling insulation, all HVAC ducting in the attic space and start over. The facility was already beyond its finish date with patients scheduled for placement.

Solution:
Based on our extensive testing on wood assemblies to 1 and 2 hour testing standards, theFF88 coating was applied to all wood ceiling truss members and roof sheathing to meet a 1 hour fire rating as required by the Georgia State Fire Marshal’s office. The work was completed in 3 weeks allowing the building to open with an extensive savings on time and cost.


Project: University of Georgia

Fire rate the 1/2" celotex ceiling tiles at the ceiling (20,000 sq.ft.) of the new computer building remodel.

Problem:
The tiles are highly flammable. The original solution was to remove all of the tiles and install and finish a new gypsum board ceiling. The university was on a tight budget financially and for time to open the facility for the new school year. The sheetrock solution would have taken 8 to 10 weeks at substantial cost.

Solution:
Based on our testing of ceiling tiles at Factory Mutual, the coating was approved for use to meet the required fire rating. The coating was completed in 5 working days at a savings in the range of 45% to the school.


Project: New South Wales Department of Housing, Australia

The province of New South Wales, which encompasses the city of Sydney, has a tremendous amount of public housing that is not up to the fire codes.

Problem:
How to upgrade thousands of residential units at a reasonable cost and without relocating residents.

Solution:
Firefree coating went thru a series of tests to make sure the units could be brought up to code. It was found that Firefree coating would bring the old ceiling assemblies to 1 hour rating. Upgrade work was completed at a fraction of the cost as compared to adding gypsum and with NO relocation of the residents.

As an update, there have been 5 fires in these residential units and none caused any major structural damage or personal injuries.

Project: Walt Disney Museum, Presidio, San Francisco, CA

The new Walt Disney museum was being constructed within a historical building within the Presidio in San Francisco. The museum wanted to preserve the existing wood ceilings and leave them exposed to retain the character of the existing building. The finish ceilings were to be finished with specific colors in keeping with the time period of the building.

Problem:
The exposed existing wood joist and wood sub-floor were required to meet a 1 hour fire rating. The only solution proposed by the City of San Francisco was to install 2 layers of gypsum board, which would not meet the intent of historical preservation wanted by the Disney Corporation.

Solution:
Based on the extensive testing on wood assemblies to 1 and 2 hour testing standards, and in fire testing performed for the City of San Francisco, the FF88 coating was applied to all wood ceiling joists and sub-floor areas to provide the required 1hour rating at a savings of 30% compared to the alternate solution. More importantly, the coating was tinted to the colors as specified by the Disney Corporation and maintained the historical look desired for the museum.

Project: Medical Offices, Pleasanton, CA

Upgrading the top floor (15,000 sq. ft.) of an existing office building for use as a medical office and surgery center.

Problem:
With the change of use, a new fire rating was required for the medical facility, The glu-lam support beams and wood ceiling framing above the suspended “T” bar ceiling required a 1 hour fire rating. To apply 2 layers of gypsum board to the ceiling would have required removal of the suspended ceiling, all HVAC ducts and electrical conduit and light fixtures. The cost and time to affect that method of repair was such that the client was going to forego the project.

Solution:
Based on the extensive testing on wood assemblies to 1 and 2 hour testing standards, the FF88 coating was applied to all glu-lam support beams and the roof/ceiling areas to provide the required 1 hour rating. The cost to do the work was reasonable enough for the client to do the work and complete the remodel of the building. The coating application took approximately 10 working days.


Project: VA Palo Alto Hospital Center for the Blind, Menlo Park, CA

While in the process of construction, it was determined that the original contractor had constructed a defective roof assembly.

Problem:
The roof was designed and constructed to encompass 6 modular medical office building modules. The constructed roof assembly did not meet the 1 hour fire requirements and the contractor was relieved of his duties and a search for solutions that would not require demolition and reconstruction was instigated by Collins and Associates, a fire safety engineering firm of Ventura, CA.

Traditional Solution:
Remove, store and reinstall all of the previously installed HVAC units, ductwork and overhead utilities. Demolish the existing roof structure, redesign and reconstruct. This would create a delay and unreasonable costs in providing the facilities for the benefit of the hospital and the Veterans Administration.

Firefree Solution:
Firefree88 was proposed and accepted to be applied to the underside of the existing roof sheathing and roof structure. This process was completed in less than 4 weeks and did not extend nor delay the original construction time frame.


Project: Live Oak Auditorium, Morgan Hill, CA

Approved by the City of Morgan Hill and the California State Department of School Architecture. Structural and Fire Safety Retrofit of a condemned auditorium to current codes. Project was jointly funded by the Live Oak School District and the City of Morgan Hill for joint use by the schools Music and Arts Department and the community of Morgan Hill.

Problem:
Upgrading of the deficient wood roof and ceiling structure required an upgrade to a 1 hour roof assembly system.

Traditional Solution:
The traditional method of an additional 2 layers of fire rated gypsum wallboard would add 4# per square foot of mass suspended over 20’ above the existing auditorium and subjected the existing shear values to non code compliant stress. Use of the traditional method would require costly upgrades to existing columns and footings as well as removal and reinstallation of existing utility lines.

Firefree Solution:
Firefree88 was applied to the existing wood roof sheathing, the supporting purlins and the structural wood glu-laminated beams to provide the 1hour rating. The cost and time savings realized by the use of Firefree88 brought the budget into consideration and resulted in the project being completed and it is currently serving the students and community of Morgan Hill.

Project: Barracks, Fort Bragg, North Carolina

The Army was upgrading the quality and fire safety of the barracks at Fort Bragg. The walls and ceilings were now required to meet new fire rating standards

Problem:
Due to the age of the buildings and the materials originally used to finish the walls and ceilings, to bring the building up to current fire standards would have required the rebuilding of all walls and ceilings. This would have required removal of all base board and door trim, reworking the stairwell areas and adding an additional layer of gypsum board to all wall and ceiling areas. This created an expensive and time consuming repair.

Solution:
Based on our extensive 1 & 2 hour testing on gypsum walls and ceilings and lath and plaster walls, The Ff88 coating was approved and used to provide the required fire ratings to the walls and ceilings of the retrofitted barracks. The savings in both cost and time was substantial.


Project: Iraq

The US military was constructing structures that consisted of finished plywood walls and ceiling.

Problem:
Since the structures were to be occupied, a fire rating was required on the plywood. The cost to overlay the plywood with gypsum board was impractical due to the cost of shipping and labor constraints due to time required to install and finish gypsum.

Solution:
Based on testing performed at Factory Mutual on plywood, The FF88 coating was approved and used to coat the plywood. The installation time and the colored finish met the military’s needs with a cost effective solution.


Project: San Domenico School, San Anselmo, CA

San Domenico is a private school in Marin County with students that commute to the school and some that live at the school.

Problem:
The school decided to do provide more fire protection to the dorm rooms where the students live. Adding sheetrock, to improve fire safety, to all the walls and ceilings was very expensive and time consuming.

Solution:
Firefree coating was used to paint all the rooms which added much need fire protection and a fresh new look to all the rooms at a fraction of the cost.


Project: Camino Colegio Property, Rohnert Park, CA

This was a 29 unit condominium project.

Problem:
Defective fire separation walls and ceilings.

Traditional Solution:
Store or protect occupants furniture and personal items. Relocate occupants for the duration of repairs. Remove all wood mouldings and trim. Remove existing stairs and modify existing intersecting walls. Add an additional layer of fire rated drywall. Reconstruct intersecting walls. Reinstall existing stair superstructures. Tape and texture all new drywall. Repaint walls and ceilings and reinstall salvageable wood mouldings and trim. Construction time frame for completion of the interiors of each unit was an anticipated minimum of 1 month in each unit. Actual work was targeted for 3 units concurrently or a total of 10 months.

Firefree Solution:
Firefree88 was employed to paint defective ceilings and fire walls without the necessity of relocation, demolition, and installation of new drywall, mouldings and stairs. Actual construction time frame for each unit was anticipated at 2 days or a total time frame of approximately 3 months. The 1 bedroom units were completed in a single day. The complete construction schedule for all phases was reduced by 8 months Total savings of $319,000.00 for labor and material was augmented by an additional savings of $240.000.00 in General Conditions due to the reduced construction schedule. Additional savings and personal enjoyment were realized for the home owners by the elimination of costs for relocation.


Project: Indian Housing, Bering Strait, Alaska

Low income housing for Indian tribes was constructed using foam composite panels.

Problem:
Bring foam composite panels up to local fire code.

Traditional Solution:
Installation of sheetrock would have increased the cost for labor and material due to the high cost to transport the sheetrock to the job site. Also, due to time restrictions, no labor force was available. This solution would have taken 2 weeks per unit.

Firefree Solution:
Apply 20 mils dry of Firefree88 to the walls and ceilings. The project was completed in 2 working days (instead of 2 weeks per unit) and at a 70% cost savings ($11,000.00 per unit savings).