Fire-Resistant Building Projects Utilizing Rock Wool and Calcium Silicate Boards
Project Overview
A high-rise commercial building required a fire-resistant renovation to enhance occupant safety, structural integrity, and compliance with fire regulations. The project focused on fire-rated walls, ceilings, and insulation systems, utilizing rock wool and calcium silicate boards for optimal fireproofing, thermal insulation, and soundproofing.
1. Fire Safety Challenges in the Building
Before renovation, the building faced several fire-related risks:
❌ Non-Fire-Rated Walls & Ceilings – Existing materials did not meet fire resistance standards.
❌ High Fire Spread Risk – Poor compartmentalization increased fire propagation risks.
❌ Low Structural Integrity Under Fire – Materials weakened under high temperatures.
❌ Inadequate Smoke Control – Poor insulation allowed toxic smoke leakage, endangering occupants.
Solution: Implementing Rock Wool & Calcium Silicate Boards
To address these challenges, the fire-resistant design included:
✅ Rock Wool Insulation (Fireproof & Heat Resistant) – Installed in walls, ceilings, and HVAC ducts.
✅ Calcium Silicate Boards (Fire-Rated Panels) – Used for fireproof partition walls and ceilings.
2. Material Selection & Application
(1) Rock Wool Insulation: Passive Fire Protection & Thermal Efficiency
✅ Material Used: High-density fire-resistant rock wool (A1-rated, 120kg/m³ density)
✅ Installation Areas:
Fireproof Partition Walls – Rock wool between double-layer calcium silicate boards for fire resistance up to 2 hours.
Ceiling & HVAC Ducts – Rock wool insulation around ducts to prevent heat transfer and smoke spread.
Structural Steel Protection – Encased steel beams with rock wool fire wraps to maintain structural integrity in fires.
✔ Why Rock Wool?
✅ Non-combustible (A1 Fire Rating, 1000°C resistance) – Prevents ignition and heat transfer.
✅ Excellent Thermal Insulation (0.035 W/m·K) – Reduces energy consumption in buildings.
✅ Soundproofing (NRC 0.8) – Reduces noise pollution in offices and commercial spaces.
✅ Moisture & Mold Resistant – Ensures long-term performance in humid conditions.
(2) Calcium Silicate Boards: High-Strength Fireproof Walls & Ceilings
✅ Material Used: 25mm fire-rated calcium silicate boards (EN 12467 certified)
✅ Installation Areas:
Interior Fire-Resistant Partition Walls – Replaced non-fire-rated drywall with calcium silicate boards + rock wool insulation.
Fireproof Ceiling Systems – Installed suspended fireproof ceiling panels to prevent flame spread.
High-Risk Areas (Stairwells, Escape Routes, Boiler Rooms) – Used 60-90 min fire-resistant panels.
✔ Why Calcium Silicate Boards?
✅ High Fire Resistance (60-180 min protection) – Ensures safe evacuation in fire emergencies.
✅ High-Strength & Impact Resistance – Suitable for high-traffic commercial areas.
✅ Non-Toxic Smoke Emission – Prevents the release of toxic gases.
✅ Moisture & Mold Resistance – Long-lasting performance in humid environments.
3. Measurable Outcomes & Fire Safety Improvements
| Metric | Before Renovation | After Renovation |
|---|---|---|
| Fire Resistance Rating | 30 min (low) | Up to 180 min (high) |
| Structural Integrity in Fire | Prone to collapse | Rock wool insulation protected steel beams (1000°C resistance) |
| Smoke Containment | Uncontrolled spread | Sealed compartments with rock wool & calcium silicate barriers |
| Thermal Insulation Performance | High heat loss | Energy efficiency improved by 25% |
| Noise Reduction (STC Rating) | STC 35 (poor) | STC 55+ (excellent soundproofing) |
| Moisture Resistance | Prone to mold | Mold-resistant materials, ensuring durability |
4. Key Takeaways & Best Practices
✔ Use high-density rock wool (120kg/m³+) for walls, ceilings, and structural fire protection.
✔ Combine rock wool with calcium silicate boards for fireproof partitions (up to 180 min fire rating).
✔ Seal HVAC ducts and stairwells with fireproof insulation to prevent smoke spread.
✔ Ensure fire-resistant walls in escape routes and high-risk areas (stairwells, electrical rooms).
✔ Select non-toxic, moisture-resistant fireproof materials for long-term durability.
5. Conclusion
The renovation successfully transformed the commercial building into a fire-resistant, thermally efficient, and soundproof environment. By integrating rock wool insulation and calcium silicate boards, the project achieved enhanced fire safety, energy efficiency, and compliance with international fire protection standards.
This case study demonstrates how modern fire-resistant materials can significantly reduce fire hazards while improving overall building performance.