Bsi bs en 01858 2008 + a1 2011

7.4.2 When tested as described in A.2 for flue blocks having a manufactured height equal to or greater than 1 000 mm, the limit deviation shall not be greater than 0,5 % of the manufact

National foreword

This British Standard is the UK implementation of EN 1858:2008+A1:2011

It supersedes BS EN 1858:2008 which is withdrawn

The start and finish of text introduced or altered by amendment is indicated in the text by tags Tags indicating changes to CEN text carry the number of the CEN amendment For example, text altered by CEN

amendment A1 is indicated by !"

The UK participation in its preparation was entrusted to Technical Committee B/506/4, Chimneys and their components having inner linings of concrete

National annex NA (informative), clauses NA.1 to NA.5, give recommendations for design and construction of Type B, concrete flue block systems for gas appliances in the UK Clause NA.6 gives examples of abbreviated designations used in the UK for common types of concrete flue blocks

NOTE Following the revision of Approved Document J to the Building Regulations in October

2010, bonding blocks for gas fire installation - Radiant/convector, ILFE or DFE require the designation T300, N2, O, D, 1.

A list of organizations represented on this committee can be obtained on request to its secretary

This publication does not purport to include all the necessary provisions of

a contract Users are responsible for its correct application

Compliance with a British Standard cannot confer immunity from legal obligations.

This British Standard

was published under the

authority of the Standards

Policy and Strategy

NORME EUROPÉENNE

English Version

Chimneys - Components - Concrete flue blocks

Conduits de fumée - Composants - Conduits de fumée

simple et multiparois en béton

Abgasanlagen - Bauteile - Betonformblöcke

This European Standard was approved by CEN on 1 November 2008 and includes Amendment 1 approved by CEN on 14 May 2011 CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN member

This European Standard exists in three official versions (English, French, German) A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom

EUROPEAN COMMITTEE FOR STANDARDIZATION

C O M I T É E U R O P É E N D E N O R M A L I S A T I O N

E U R O P Ä I S C H E S K O M I T E E FÜ R N O R M U N G

Management Centre: Avenue Marnix 17, B-1000 Brussels

© 2011 CEN All rights of exploitation in any form and by any means reserved

worldwide for CEN national Members

Ref No EN 1858:2008+A1:2011: E

Contents

Foreword 4



1





2





3





4





4.1





4.2





5





6





7





7.1





7.2





7.3





7.4





7.5





8





8.1





8.2





8.3





8.4





8.5





8.6





8.7





8.8





8.9





8.10





8.11





8.12





8.13





8.14





9





9.1





9.2





9.3





9.4





9.5





9.6





10





11





12





12.1





12.2





12.3





12.4





A.1





A.2





A.3





A.4





A.5





A.6





A.7





A.8





A.9





A.10





A.11





Annex B (informative) Examples of concrete flue block shapes 39



B.1





B.2





B.3





Annex C (normative) Thermal resistance calculation method 43



C.1





C.2





Annex D (normative) Requirements of sampling plan according to ISO 2859-1:1999 at an Acceptable Quality Level (AQL) of 10 % and inspection level S2 44



D.1





D.2





D.3





D.4





D.5





D.6





D.7





Annex E (informative) Recommended test sequence 48



Annex ZA (informative) Clauses of this European standard addressing the provisions of the EU Construction Products Directive 49



ZA.1 Relationship between EU Directives and this European Standard 49



ZA.2 Procedure of attestation of conformity of concrete flue blocks 51



ZA.3 CE Marking and labelling 52



Bibliography 55



Foreword

This document (EN 1858:2008+A1:2011) has been prepared by Technical Committee CEN/TC 166

“Chimneys”, the secretariat of which is held by !ASI"

This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by December 2011, and conflicting national standards shall be withdrawn

at the latest by March 2013

Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights

For the relationship with the EU Directives, see informative Annex ZA, which is an integral part of this standard

In this European Standard, the Annexes A, C and D are normative (not forming part of the product specification) and Annexes E and ZA are informative

This document includes Amendment 1 approved by CEN on 14 May 2011

The start and finish of text introduced or altered by amendment is indicated in the text by tags !"

This document supersedes !EN 1858:2008"

This Standard is one of a series of co-ordinated standards dealing with specification, design, testing and installation of chimneys, both single and multi wall

The co-ordinated package of standards is further divided by material of construction and this European Standard

is one of a series of specifications and execution documents dealing with design and installation of concrete chimney products and systems

The standards in this series for concrete chimney products and systems are:

EN 1857, Chimneys — Components — Concrete flue liners;

EN 1858, Chimneys — Components — Concrete flue blocks;

EN 12446, Chimneys — Components — Concrete outer wall elements

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom

1 Scope

This European Standard specifies the materials, dimensional and performance requirements for precast

concrete flue blocks as defined in Clause 3 for use in !deleted text " chimneys The flue blocks may be of

single wall or multi wall construction The standard does not apply to flue blocks with back ventilation

This standard does not cover products designated wet (W) in conjunction with corrosion class 3

The standard also specifies a type of flue block to dimensionally co-ordinate with masonry unit coursing height, referred to as a type B (Bonding block)

This European Standard also applies to storey-height and flue blocks reinforced for handling

NOTE Any reference to the term flue blocks implies both flue blocks and their fittings, except where otherwise indicated

2 Normative references

The following referenced documents are indispensable for the application of this document For dated references, only the edition cited applies For undated references, the latest edition of the referenced document (including any amendments) applies

EN 206-1: 2000, Concrete — Part 1: Specification, performance, production and conformity

EN 1443, Chimneys — General requirements

EN 10088-2, Stainless steel — Part 2: Technical delivery conditions for sheet/plate and strip of corrosion resisting

steels for general purposes

EN 13216-1, Chimneys — Test methods for system chimneys — Part 1: General test methods

EN 13384-1, Chimneys — Thermal and fluid dynamic calculation methods — Part 1: Chimneys serving one

appliance

EN 14297: 2004, Chimneys — Freeze-thaw resistance test method for chimney products

EN ISO 7500-1:2004, Metallic materials — Verification of static uniaxial testing machines — Part 1:

Tension/compression testing machines !(ISO 7500-1:2004)"

ISO 2859-1:1999, Sampling procedures for inspection by attributes — Part 1: Sampling schemes indexed by

acceptance quality limit (AQL) for lot-by-lot inspection

3 Terms and definitions

For the purposes of this European Standard, the terms and definitions given in EN 1443 and the following apply

3.1

flue block fitting

element fitted to the flue block such as an access opening or offset

3.2

hollow wall flue block

flue block having vertical cavities

NOTE Cavities may pass through both ends of the block

3.3

manufacturer's declared internal transverse dimension

internal dimension of the flue block measured perpendicular to the longitudinal axis

3.4

manufacturer's declared height

internal height of the flue block

NOTE Examples of measurement are shown in Figure 1

manufacturer's declared structural height

maximum constructional height of the flue blocks as declared by the manufacturer

3.6

manufacturer's declared overall wall thickness

dimensions at its thinnest point, between the inside face of the flue and the outside face of the flue block, not measured at any joint feature, e.g spigot/socket end

3.7

multi wall flue block

flue block consisting of a flue liner and at least one additional wall

3.8

reinforced flue block

flue block having reinforcement to assist handling (not for structural stability)

3.9

solid wall flue block

flue block without cavities in the thickness of its walls

3.10

straight flue block

flue block designed to be used in a vertical section of a chimney, without having any special characteristics and having the ends perpendicular to the axis of the flue

3.11

storey-height flue block

factory made flue block having an overall height relating to the floor to floor height of a building

type B flue block

type B (Bonding) block

bonding block dimensionally co-ordinated with masonry unit coursing height, and having a designation T250,

N, D1, O xx (see Clause 9)

4 Materials

4.1 General

The wall or walls of flue blocks shall be precast concrete For multiwall flue blocks the liner and outer wall may

be separated by an air space or insulation

Materials used in the manufacture of flue blocks shall be identified for factory production control purposes

When insulation forms part of a flue block, it shall be of bonded material as specified by the manufacturer If the insulation is supplied as a separate item, it shall be installed in accordance with the flue block manufacturer’s installation instructions

The manufacturer shall declare the bulk density of the flue block and when tested to A.10 the density shall be within ± 10 % of the declared value (see 8.9)

4.2 Reaction to fire

In accordance with Commission Decision 96/603/EC, as amended, flue blocks to this standard are classified

as reaction to fire class A1 without test provided, they contain not more than a mass or volume fraction of 1 % (whichever is the more onerous) of homogeneously distributed organic materials

5 Reinforcement for handling

5.1 Where a flue block is reinforced for handling, the reinforcement shall have a maximum diameter of

8 mm and a minimum concrete cover of 15 mm on all sides for temperature classes up to and including T250 and a minimum concrete cover of 20 mm on all sides for all other temperature classes

5.2 In flue blocks having a bulk density of less than 2 000 kg/m3, when measured in accordance with Clause A.10, any reinforcement shall be protected against corrosion by one of the following means:

a) use of stainless steel;

b) by completely covering any mild steel reinforcement with a coating (e.g typically Portland cement CEM I

or CEM II mixed with water to form a slurry, or epoxy resin)

NOTE See Annex B for examples of typical flue block types

7.1.2 Flue blocks shall have a maximum of four flues or ventilation passages

7.2 Type B flue blocks

7.2.1 The co-ordinating height of Type B flue blocks shall be declared by the manufacturer

NOTE The co-ordinating height is the height of the flue block plus an allowance for jointing so that the flue block will align with one or more specified coursing heights in a brick or block wall See Figure 2

7.2.2 When measured perpendicular to the axis of the flue for Type B flue blocks, the minimum dimensions

of the flue shall be not less than 90 mm and the cross-sectional flue area shall be not less than 16 500 mm2

In transfer blocks, the flue shall taper to a diameter of not less than 125 mm

7.2.3 The bonding extension on straight bonding Type B flue blocks shall not be less than 75 mm

(see Clause B.3)

7.2.5 Starter Type B flue blocks shall have internal transverse dimensions not less than 305 mm side ×

115 mm deep (see Clause B.3)

7.2.6 When jointed together in accordance with the manufacturer's installation instructions, the flue in

adjacent Type B flue blocks shall align to within 3 mm

7.3 Tolerances

Tolerances on manufacturer's declared dimensions, including taper, shall be:

a) Declared internal transverse dimensions

c) Declared overall wall thickness

below 10 mm :

+ 1 2 mm

−

10 mm to 40 mm :

+ 1,5 5 mm

−

+ 12 5 %

−

7.4 Straightness

7.4.1 When tested as described in A.2, the limit deviation from straightness of a straight concrete flue block

of manufacturer's declared height greater than 300 mm and less than 1 000 mm shall not be greater than 1 %

of the declared height

7.4.2 When tested as described in A.2 for flue blocks having a manufactured height equal to or greater than

1 000 mm, the limit deviation shall not be greater than 0,5 % of the manufacturers declared height

7.5 Squareness of ends

When tested in accordance with either procedure described in A.1, the test sample shall not touch the upright for the first procedure and the dimension G shall not be greater than 5 mm for the second procedure

8 Performance

8.1 Heat stress resistance

8.1.1 When flue blocks and fittings, including those designated soot fire resistant, are tested in accordance

with A.3 at the test temperature appropriate to the designation specified in Table 1, the flue block shall subsequently meet the requirements of 8.4 In addition, flue blocks and fittings having a compressive strength less than 10 MPa, or having a temperature designation above T250 and/or designated soot fire resistant, shall meet the requirements of 8.5

When a flue block is multi-flued with an equal wall thickness, the heat stress test shall be carried out on the flue with the highest designation and temperature

8.1.2 Flue block bends, made of the same material mix and by the same method of manufacture as the

tested straight flue block shall be deemed to comply with the requirement in 8.1.1

8.1.3 Flue block bends and fittings, made of a different material mix or using a different method of

manufacture from those described in 8.1.2, shall be checked for heat stress resistance by testing a special straight test sample in accordance with 8.1.1 This straight test sample shall be made using the same material mix and manufacturing method as the bend or fitting

8.1.4 The distance to combustible material, xx, shall be declared The maximum temperature measured on

the surface of adjacent combustible materials shall not exceed 85 °C when related to an ambient temperature

of 20 °C

8.2 Heat shock resistance

8.2.1 Following the heat stress resistance test in 8.1, when a flue block designated as soot fire resistant is

tested as described in A.3 at a flue gas temperature of 1 000 °C for a period of 30 min ± 1 min, the block shall subsequently meet the requirements of 8.4 In addition, flue blocks and fittings having a compressive strength

less than 10 MPa, or having a temperature designation above T250 and/or designated soot fire resistant shall meet the requirements of 8.5

8.2.2 Flue block bends made of the same material mix and by the same method of manufacture as the

tested straight flue block, shall be deemed to comply with the requirement in 8.4

8.2.3 Flue block bends and fittings, made of a different material mix or using a different method of

manufacture from those described in 8.2.1, shall be checked for heat shock by testing a special straight test in accordance with 8.1.1

8.2.4 The distance to combustible material, xx, shall be declared The maximum temperature measured on

the surface of adjacent combustible materials shall not exceed 100 °C when related to an ambient temperature of 20 °C, when the test assembly is tested at the test temperature of 1 000 °C over a period of

30 min

Table 1 — Heat stress test temperature

Temperature group Temperature of flue gas

8.5 Abrasion resistance

All flue blocks having satisfied the gas tightness requirements of 8.4, when tested as described in A.6, the weight

of the deposit collected shall not exceed the values in Table 2, and shall subsequently meet the gas tightness requirements of 8.4

Table 2 — Abrasion resistance

8.6.1 The manufacturer shall declare the structural height When tested as described in A.7, straight flue

blocks and straight fittings shall withstand an intensity of loading equivalent to four times the manufacturer's declared structural height

NOTE The manufacturer's declared structural height can be derived from the ultimate compressive strength determined by the method in Clause A.11

Type B flue blocks shall be tested as a complete element and shall not be cut

8.6.2 Flue block bends and fittings, made of the same material mix and by the same method of manufacture

as the tested straight flue block, shall be deemed to comply with the requirement in 8.6.1

8.6.3 Flue block bends and fittings, made of a different material mix or using a different method of

manufacture from those described in 8.6.2, shall be checked for compressive strength by testing a special straight test sample in accordance with 8.6.1

The special straight test sample shall be made using the same material mix and manufacturing method as the bend or fitting

8.7 Corrosion resistance

When flue blocks designated condensate resistance class W (suitable for use in wet operating conditions) are tested as described in Clause A.8, flue blocks shall be designated corrosion class 1 or class 2 depending on the test solution used, provided that the mass loss of the test pieces is not greater than 0,1 % of the initial mass

Flue blocks designated condensate resistance class D (dry) and which meet the requirements of 8.1, 8.3, 8.5, and 8.6, may be assigned corrosion resistance class 3

8.8 Condensate resistance

When flue blocks designated W (for use in wet operating conditions) are tested as described in Clause A.8, the maximum amount of test solution passing through the wall of the flue block during any 24+2 h test period shall not be greater than 0,5 gh-1m-2 of the flue block external surface

8.9 Bulk density

When flue blocks are tested as described in Clause A.10, the lowest and highest bulk density value shall be within a limit deviation of ± 10 % of the manufacturer's declared bulk density for the block

8.10 Flexural strength under wind loading

The maximum free standing height of flue blocks shall be no greater than 4,5 times the least lateral overall external dimension of the flue block from the last point of lateral support (see Figure 3)

Alternatively, the free standing part of the chimney above the last lateral support of the concrete flue block shall withstand a wind load of 1,5 kN/m2 (or a value in accordance with national regulations), when tested in accordance with A.9

1 top of chimney excluding any terminal or chimney pot

2 last point of support

l least lateral overall external dimension of the flue block

Figure 3 — Explanation of last point of support

8.11 Flow resistance

8.11.1 Flow resistance of straight flue blocks

The mean value of roughness for a straight flue block shall be determined either:

a) by testing in accordance with EN 13216-1, or

b) from data obtained from EN 13384-1

8.11.2 Flow resistance of fittings

The coefficient of flow resistance due to a directional and/or cross sectional and/or mass flow change shall be determined either:

a) by testing in accordance with EN 13216-1, or

b) from data obtained from EN 13384-1

8.12 Freeze-thaw resistance

Where national regulations require freeze/thaw resistance of flue blocks, they shall be tested in accordance with EN 14297 The product shall not present any damage of type 7, 8, 9 and 10 in accordance with

EN 14297:2004, Table 1

8.13 Resistance to fire external to external

Where national regulations require resistance to fire external to external (see EN 1443) of flue blocks, they shall be evaluated and declared in accordance with those regulations

8.14 Dangerous substances

Materials used in products shall not release any dangerous substances in excess of the maximum permitted levels specified in a relevant European Standard for the material, or permitted in the national regulations of the member state of destination

NOTE See note 2 in Annex ZA.1

9 Designation

9.1 General

All concrete flue blocks conforming to this standard shall be designated in accordance with 9.2 to 9.6 for temperature, pressure, resistance to soot fire, condensate resistance and corrosion resistance respectively NOTE An example of a designation system is given in Figure 4

EN 1858 T 120_ N2 D 3 O (20)The number of this standard

Flue gas temperature class

Negative/positive pressure class

Resistance to condensate

Corrosion resistance

Resistance to fire [G(xx) or O(xx)]

Figure 4 — Example of a designation system

9.2 Temperature class

The temperature class shall be as given in Table 3

Table 3 — Temperature class Temperature class Nominal working temperature

 for flue blocks suitable for positive pressure chimneys: P1, P2;

 for flue blocks suitable for high positive pressure chimneys: H1, H2

Table 4 — Pressure classes and gas tightness Pressure class Test pressure

Pa Maximum leakage rate Gas tightness –

l/s/m2

P1 200 0,006 P2 200 0,120

9.4 Resistance to fire class

Resistance to fire class shall be as follows:

 O (xx) for flue blocks for chimneys without sootfire resistance;

 G (xx) for flue blocks chimneys with sootfire resistance

9.5 Resistance to condensate class

The resistance to condensate class shall be as follows:

 W for flue blocks for chimneys intended to operate under wet conditions;

 D for flue blocks for chimneys intended to operate under dry conditions

9.6 Corrosion resistance class

Corrosion resistance classes for chimneys which convey products of combustion from gas or light oils and natural wood or heavy oils and solid mineral fuels shall be as given in Table 5 (see 8.7)

Table 5 — Corrosion resistance classes

Fuel

Types 1 possible fuel types 2 possible fuel types 3 possible fuel types

gas gas: sulphur-content

≤ 50 mg/m3

natural gas L + H

gas natural gas L + H

gas natural gas L + H

liquid kerosene: sulphur-content

wood wood in open fire places wood in open fire places

wood in closed stoves

NOTE Table 5 does not categorize process gases or liquids

10 Marking

A minimum of 20 % of the flue blocks or fittings in each consignment shall be legibly and indelibly marked with the following information:

a) name or trademark of the manufacturer;

b) manufacturers batch or date code;

c) number of this European Standard;

d) designation in accordance with Clause 9;

e) arrow indicating direction of flue gas flow;

f) identification of the flue in a flue/air duct combination block

NOTE For CE marking and labelling, Clause ZA.3 applies

11 Product information

The manufacturer's printed literature for the product shall include the following:

a) manufacturer's product description;

b) manufacturer's declared sizes;

h) detailed installation instructions including method of jointing and flue identification

NOTE For CE marking requirements for information on the product, Clause ZA.3 applies

12 Evaluation of conformity

12.1 General

The compliance of the concrete flue blocks with the requirements of this standard and with the stated values (including classes) shall be demonstrated by:

 initial type testing,

 factory production control by the manufacturer, including product assessment

12.2 Initial type testing

Type test relating to material composition shall be performed initially together with factory production control tests as given in Table 6 One test shall be carried out for each requirement

The thermal testing shall be carried out on one size of flue block for each geometrical configuration, e.g circular, square, rectangular For circular flue blocks, the size to be tested shall be 200 mm ± 50 mm internal diameter For other geometrical configurations, the flue block shall have an equivalent cross-sectional area range

12.3 Further type tests

Type tests shall be performed when a change is made either in material composition, processing technique or

to the design or method of manufacture of the flue block, but they may be performed more frequently by incorporation into a plan for monitoring the consistency of manufacture (see Table 6)

Table 6 — Factory production control and type tests

Item

Relevant requirement clauses

Factory production control

12.4 a 12.2 and 12.3 Type tests Flue blocks and fittings 4, 5, 6, 7.2, 7.3, 7.4, 7.5, 8.4,

8.6, 8.9 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.10, 8.11, 8.12

a The tests carried out during FPC are intended to verify that the performance requirements assessed through

the initial type testing are maintained

12.4 Factory production control

To achieve compliance with this standard, the manufacturer shall establish and maintain an effective documented quality system

Factory production control tests are carried out following manufacture to monitor the quality of product (see Table 6)

Sampling and testing of any batch shall be completed prior to removal from the works and shall be in accordance with ISO 2859-1:1999 at an AQL of 10 % and inspection level S2 Isolated batches of units shall

be assessed in accordance with tightened inspection procedures, with a maximum batch size of 2 500 (see Annex D)

Batches rejected under the factory production control procedure may be resubmitted once, after removal of units with previously undetected visible defects, under the tightened inspection procedures, in respect only of the defect that caused initial rejection

NOTE A quality system assessed by a certification body which complies with the requirements of EN ISO/IEC 17021 [1] may be applied to ensure that the requirements of EN ISO 9001 [3] and Clause 12 are complied with

Annex A

(normative)

Test methods

NOTE Annex E gives the recommended test sequence

A.1 Squareness of ends test

A.1.1 Apparatus

The apparatus shall include the following:

A.1.1.1 A level test bench with a fixed upright at 90°, see Figure A.1 a);

A.1.1.2 A square having one arm 300 mm long and the second arm 400 mm long

2 adjustable cantilevered straight edge

3 level test surface

5 dimension in mm

G dimension in mm

Figure A.1 — Apparatus for squareness test

A.1.2 First procedure

Place the flue block upright on the test bench with the base of the flue block touching the collar Rotate the flue block through 360°

A.1.3 Test result — first procedure

Record any case where the flue block touches the upright

A.1.4 Second procedure

Place the flue block upright on the test bench and apply one arm of the square along its side with the other arm touching the end of the flue block Rotate the square across the end of the flue block as shown in Figure A.1 b)

A.1.5 Test result — second procedure

Record any case where the dimension G exceeds 5 mm

A.2 Straightness test

A.2.1 Apparatus

A straightness measuring device, such as a straight edge, having a height 100 mm less than the nominal height of the flue block under test

A.2.2 Procedure

A.2.2.1 Place the measuring device along the line

H

A.2.2.2 Measure the maximum distance from the centre of the straight line created by the apparatus

in A.2.1 spanning any concave curve on the outside of the flue block surface (

D

Figure A.2 — Straightness test

A.2.3 Test result

Record any case where

D

1 000 mm in height, any case where

D

A.3 Heat stress resistance and heat shock test

NOTE The heat shock test is a method to assess the chimney for ability to resist sootfire

A.3.1 Apparatus

A heat generator capable of delivering completely combusted hot gas at the temperature specified in Table 1, having a CO/CO2 ratio not greater than 0,01 with the appropriate volume flow for the cross-section specified in Table A.1, with the heat source shielded

A.3.2 Test assembly

Construct a test sample of flue blocks to give a minimum overall height of 2,0 m jointed in accordance with the manufacturer's instructions (see Figure A.3) For flue blocks less than or equal to 1,0 m manufacturer's declared height, the assembly shall consist of a minimum of two complete flue blocks and joints Flue blocks

of manufacturer's declared height of greater than 1,0 m may be cut and the test assembly formed from two cut pieces, each having a height greater than 0,5 m and having only one joint near the centre of the assembly

E

E

A

A B

a) install the test sample in a free standing manner; or

b) install the test sample, in the test assembly as shown in Figure A.3 adjacent to the combustible partition,

at the manufacturer's declared distance to combustibles Seal the openings with non-combustible materials (sides and top, see Figure A.3), unless the manufacturer allows the gap to be ventilated The partition shall consist of nominal dimension 38 mm × 89 mm thick timbers in a framework (see Figure A.4), faced on each side with one layer of nominally 12 mm thick plywood to give a total thickness

of 114 mm ± 1,0 mm insulated in the voids, with mineral wool insulation having a thermal conductivity of 0,035 W/(m·K) ± 0,002 W/(m·K) at 20 °C ± 10 °C, with a minimum density of 70 kg/m3 ± 10 kg/m3 The walls shall extend 1 200 mm ± 12 mm

Dimensions in millimetres

89101

6411200

38

89549

1099

1188

a) — Wall Frame C Side 1 Zone B b) — Wall Frame D Side 2 Zone B

Figure A.4 — Wall frames

Test type B gas flue blocks using the test assembly described in Figure 5 where the partition is a 225 mm by

50 mm timber joist extending one masonry wall block length on either side of the flue block

NOTE Type B gas flue blocks differ from standard flue blocks as they are designed to be used within a masonry wall

In this situation, the only combustible material in proximity to the Type B blocks are the floor and ceiling joists running parallel to the wall

6 partition positioned to simulate location of combustible floor joist

7 outer wall temperature

8 partition temperature

9 minimum joist length, i.e flue block + (2 x masonry unit length)

Figure A.5 — Example of test assembly for Type B Flue Blocks

If the block has more than one passage, test the passage which has the highest temperature designation for a flue block

A.3.3 Test environment and conditioning

A.3.3.1 Test room

The test room shall provide the following conditions:

a) ambient air temperature: 15 °C up to 30 °C;

b) draughts into the test room: ≤ 0,5 m/s;

NOTE This requirement is assumed to be met by a closed room environment

c) location of measurements: minimum height of 1,0 m above the floor and at least 1,0 m from the walls; d) minimum distance between the chimneys and other structures (i.e walls): 1,0 m;

e) free connecting space if the laboratory is divided in several levels

These ambient air conditions are measured a maximum of 1,0 m from the test assembly

Limit deviation of measurements shall be:

 ± 1,5 °C for the ambient temperature;

 ± 0,05 m/s for the velocity of draughts;

 ± 0,05 m for the distances

A.3.3.2 Assembly conditioning

Condition the test assembly for a minimum of 28 days at ambient temperature, unless otherwise specified by the manufacturer, then remove all loose material by conducting 20 brush cycles as in A.6

A.3.3.3 Dry/conditioning phase

Unless otherwise specified by the manufacturer, deliver flue gases into the test assembly in such a way that the temperature, measured as described in A.3.4.1, rises to 200 °C or the nominated test temperature, whichever is the lower, in 60 min ± 5 min

A.3.4 Procedure

A.3.4.1 Establish an overall temperature distribution factor,

OTDF

OTDF

t

t

A.3.4.2 Deliver completely combusted gas, in accordance with the flow rate specified in Table A.1, into the test sample and within 10 min raise the temperature of the gas uniformly to the appropriate test temperature (see Table 1) measured at the location determined as specified in A.3.4.1

NOTE The flow rates are for heat generation from natural gas combustion

A.3.4.3 Maintain the delivery of gas until the temperature at any of the specified points of measurement does not rise by more than 2 K in 30 min (equilibrium) or to a maximum time of 4 h

For the test assembly described in A.3.2 a) the points of measurement shall be on the exposed faces of the test sample, at the mid point of a complete flue block near the centre of the assembly or at least 100 mm from

a joint For rectangular sections, the measurement shall be taken at the mid point of the longer side

For the test sample described in A.3.2 b) additional points of measurement shall be on both faces of the combustible partition at a location opposite to the mid point of the test sample and, where the space between the test sample and partition is closed, at a point 50 mm inside the space from the ends of the test sample, opposite its centre line

Allow the test sample to cool to ambient without assistance, e.g without forced ventilation

Determine the maximum temperature at the points of measurement

A.3.4.4 For the heat shock test, maintain the flue gas temperature at 1 000 50

0

+ °C for a period of (30 ± 1) min

Determine the maximum temperature at the points of measurement

A.3.4.5 Subject the test sample to the test described in A.5

A.3.5 Test results

Record the maximum temperature of the test sample, and either:

a) if the test temperature described in A.3.2 a) was used, calculate what the surface temperature of a

Table A.1 — Hot gas velocity in m/s at test temperature

Temperature classT080 T100 T120 T140 T160 T200 T250 T300 T400 T450 T600 Sootfire

Test temperature °C Pressure

separated from the test sample by the specified distance to combustible materials (as declared by the manufacturer); or

NOTE 1 A method for calculating the surface temperature of adjacent combustible material is given in EN 15287-1 [2] NOTE 2 The specified distance to combustibles may be specified in local regulations,

b) if the test assembly described in A.3.2 b) was used, record the maximum surface temperature of the combustible partition Record the leakage rate of the test sample

A.4 Thermal resistance

A.4.1 Test assembly

The test assembly consists of electric heaters, fan(s) and interconnecting tubes so that heated air can pass around the test assembly

NOTE An example of the test assembly is shown in Figure A.6

Install in each arm of the test assembly a minimum of 2 m of test chimney sections including at least two joints Bond thermocouples used to measure the internal and external wall surface temperatures to the test assembly using manufacturer jointing material

3 2

8 measuring points for temperature, pressure and velocity of circulating air

h internal surface temperatures

r external surface temperatures

▲ ambient air temperature

■ pressure and velocity A-B cross section

Figure A.6 — Thermal resistance apparatus

A.4.2 Test procedure

Circulate hot gas around the test assembly The velocity of the hot gas shall be (4 ± 1) m/s, and the hot gas temperature at the ends of the test sections shall not differ by more than 10 K

Measure the internal and external surface temperatures of the chimney sections, and the hot gas temperature

at the ends of the chimney For chimneys designated suitable for wet conditions, the hot gas shall be water vapour saturated and shall have a heat content and temperature, so that the inner surface reaches a temperature of 70 °C For chimneys designated suitable for dry conditions, the hot gas shall have a heat content and temperature so that the inner surface reaches a temperature 20 % below the designated temperature (normal working temperature), but not more than 200 °C Equilibrium is reached when the difference between the outer surface temperature of the chimney section and the ambient temperature does not change by more than 1 % in 60 min

A.4.3 Test results

Calculate the thermal resistance,

λ

1, in m2 K W-1 from the equation:

2 1

Q

Q

t

t

A

A.5 Gas tightness test

A.5.1 Apparatus

A.5.1.1 A test assembly as described in A.3.2

A.5.1.2 A means of creating a gas tight seal at each end of the test flue assembly

A.5.1.3 Two pieces of tubing passing through and sealed into one of the air-tight seals (A.5.1.2)

A.5.1.4 A fan capable of producing at least the required differential pressure, a flow meter and a manometer shall be used The air supply for the test shall be measured by a flow meter with a limit deviation

of ± 5 % of full scale The full scale reading shall be approximately the flow rate for the maximum leakage rate for the appropriate class of flue block

A.5.1.5 A pressure gauge capable of measuring pressure to a limit deviation of ± 5 %

A.5.2 Test environment and conditioning

A.5.2.1 Test room

The test room shall be as given in A.3.3.1

A.5.2.2 Assembly conditioning

Condition the test assembly for a minimum of 28 days at ambient temperature unless otherwise specified by the manufacturer

A.5.3 Procedure

A.5.3.1 Plug both ends of the test assembly with an air-tight seal At one end insert two lengths of tubing (A.5.1.2), see Figure A.7

A.5.4 Test result

Calculate the leakage rate of the assembly,

E

Q

S

t

A.6 Abrasion resistance test

A.6.1 Test assembly

The assembly of flue blocks as described in A.5.2, of 200 mm diameter (or closest size in manufacture range), which have been subjected to the heat stress and heat shock test in accordance with their appropriate temperature group designation and corrosion and condensate resistance tests

A.6.2 Preparation

Fit a tight fitting metal sleeve attached to a catchment funnel into the top opening of the test block Fit a tight fitting sleeve attached to a plate which has an opening matching the area of the opening of the block into the bottom of the test block as shown in Figure A.8

5

2

2 6

1 height of funnel not less than 200 mm

2 tight fitting sleeve projecting 20 mm to 40 mm into opening

3 bottom plate attached to bottom sleeve

4 height sufficient to allow brush to pass through bottom of

test assembly

5 catchment funnel attached to sleeve

6 collection box

7 plan of block opening area

8 plan of brush area

9 round block

10 square or rectangular block

11 rod

Figure A.8 — Abrasion test assembly

A.6.3 Test brush

If the manufacturer includes a specification for the sweeping brush in the maintenance instructions for the flue blocks, the manufacturer's declared sweeping brush specification shall be used for the abrasion resistance test

In the absence of a manufacturer's declared specification, the sweeping brush shall have flat spring-steel bristles of stainless steel in accordance with EN 10088-2, grade X10 CR NI 18-8, steel number 1.4310, with a cross section of (2,0 ± 0,1) mm × (0,3 ± 0,1) mm

The overall dimension of the brush shall be (25 ± 5) mm greater than the internal dimensions of the flue The bristles shall be arranged so that there are 5 per 10 mm length of the perimeter of the plan area of the brush The brush shall be held securely between plates having a plan dimension (100 ± 5) mm less than the cross sectional internal transverse dimension of the flue being tested

The brush shall be attached to a rod

A.6.4 Test procedure

Pass the brush down through the total height of the test assembly at a rate of 0,4 m/s, and then, at the same rate, pull the brush up through the total height of the test assembly

After constructing the test assembly as detailed in A.3.2, the flue blocks shall be conditioned by carrying out

20 brush cycles as in Clause A.3.3.2 Any material dislodged during this conditioning phase shall be discarded

After the heat stress resistance and heat shock test detailed in Clause 3, carry out a further 80 brush cycles collecting any dislodged material

A.6.5 Test result

Record the weight of any material that has been dislodged from the internal surface of the test assembly and calculate the total area of the internal surface of the flue between the sleeves

A.7 Compressive strength test

A.7.1 Apparatus

A machine having a verified accuracy as specified in ISO 7500-1:2004, Class 3, capable of applying the test load at the rate specified in A.7.3

A.7.2 Preparation of test sample

A.7.2.1 Prepare a section of flue block at least 150 mm in height or one complete flue block height if shorter than 150 mm, by sawing each end to produce flat and parallel ends, to within the tolerances specified

in 7.3, square to the axis For flue blocks having external transverse dimensions greater than 300 mm, cut by sawing a section as indicated in Figure A.9, and saw the upper and lower ends to produce flat and parallel ends, square to the axis