Every service penetration through a fire-rated wall, floor or ceiling is a potential weakness in the building's compartmentation. The pipe, cable, duct or conduit itself may burn, melt or conduct heat — creating a pathway for fire and smoke between compartments. Penetration sealing systems exist to close this weakness, but only if correctly selected, specified and installed.
Why Penetration Seals Matter
A single unsealed penetration through a two-hour fire wall can allow fire and smoke to penetrate from one compartment to another within minutes. In a multi-storey building with dozens of service penetrations per floor, the cumulative effect of poor penetration sealing practice can be catastrophic. The AS 4072.1 standard and BCA C3.15 exist to ensure every penetration is sealed to at least the FRL of the element it passes through.
Standard Requirements
AS 4072.1 (Components for the Protection of Openings in Fire-Resistant Separating Elements) specifies the requirements for systems used to protect service penetrations. BCA C3.15 requires that openings for services must be protected by a system that achieves an FRL not less than the element it passes through. The combined effect is that every penetration seal must be designed, specified and installed to match the FRL of the surrounding wall or floor.
Common Penetration Seal Product Types
- Intumescent pipe collars — for plastic pipes; expand as the pipe melts to close the penetration
- Fire-rated sealants and mortars — for cables, conduits and mixed services; fill the annular space around the service
- Fire-rated pillows — for removable seals around cable trays; allow future cable additions
- Intumescent wraps — for larger plastic pipes; wrap around the pipe and expand on heating
- Fire-rated duct collars and dampers — for mechanical ductwork penetrations
- Pre-formed seals — factory-manufactured seals for specific pipe and substrate combinations
How to Correctly Specify a Penetration Seal
The critical rule: the penetration seal must be specified and installed in a configuration that matches its tested or assessed application. Every penetration seal product has test evidence — typically a CodeMark certificate or CSIRO assessment — that specifies the exact conditions under which it achieves its rated FRL: the pipe diameter, pipe material, wall substrate, wall thickness, annular space and installation method.
Configuration is Everything
Using a product in a different configuration from its tested application does not give you the tested FRL. A sealant tested around a 100mm copper pipe through a 200mm concrete wall cannot be assumed to achieve the same FRL around a 100mm PVC pipe through a 90mm lightweight wall — even if it is the same brand. Always check the test evidence for your specific configuration.
Documentation Requirements
For each penetration seal, the following must be documented: the penetration reference number and location; the service type, size and material; the seal system used including product name and manufacturer; the test evidence reference (CodeMark number, CSIRO report reference); the FRL achieved; the installation date and installer details; and photographic evidence of the installed seal before any covering works.
This documentation forms the as-built penetration register that must be available to the AFSP for AFSS assessment. Without it, the AFSP cannot verify that penetration seals were installed correctly and to the required FRL — and may be unable to certify the passive fire protection measure.
Put This Into Practice
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