Method Statement: Spray-Applied Cementitious Fireproofing (SFRM)

Q: How is the required SFRM thickness determined?

Thickness is derived from the approved UL/EN design listing based on member section factor (W/D or Hp/A) and the required fire-resistance rating. Always verify per project specifications and manufacturer guidance.

Q: What are typical acceptance criteria for adhesion and density?

Adhesion per ASTM E736 typically benchmarks at ≥150 psf (≈7.2 kPa), and density must meet the product’s specified range (often within ±15%). Verify values in the project specifications and product data.

Q: Can SFRM be applied over primed steel?

Yes, if the primer is compatible. Obtain a written compatibility confirmation from the SFRM manufacturer. Some primers, such as zinc-rich types, may require bonding agents or special preparation.

Q: What environmental conditions are required during application?

Typical limits are substrate/ambient temperatures between 4–43°C, RH <85%, and no condensation (substrate at least 3°C above dew point). Always verify per the product data sheet.

Q: How often should thickness, adhesion, and density be tested?

Thickness is checked on a defined grid per area/member. Adhesion tests are commonly 1 per 930 m² per area/day, and density tests 1 per 465 m² per product/day. Confirm frequencies with the ITP and project specs.

More than a static template

Unlike a downloadable Word or PDF template, this method statement is an AI-assisted editable starting point connected directly to a matching Inspection and Test Plan. Every section is structured, project-adaptable, and ready to export.

AI-assisted drafting — Customize every section with AI for your specific project scope.
Linked ITP — A matching inspection and test plan is generated alongside the method statement.
Multiple export formats — Download as a formatted PDF or editable Excel spreadsheet.
Editable starting point, not a final document — Review, verify, and adjust all content against your project requirements before use.

Static template vs. Quollnet workflow

Feature	Static template	Quollnet
Project-specific content	Manual fill-in required	AI-assisted customization
Linked ITP	Separate document, no link	Matching ITP included
Export formats	Usually PDF only	PDF and Excel
Structured sections	Free-form layout	13 standardized sections
Saved to your account	Local file only	Cloud-saved, reusable
Content accuracy	You verify everything	AI-assisted, you still verify
Cost	Often free but time-intensive	Free to customize and download

What you can customize

When you save this method statement to your account, every section becomes editable. The following 13 sections are included:

Scope — Defines the activity and its boundaries.
References — Standards, specifications, and drawings.
Responsibilities — Roles and accountabilities.
Resources — Labour, plant, and equipment summary.
Materials — Materials and compliance requirements.
Equipment — Tools and equipment details.
Prerequisites — Hold points and pre-conditions.
Method sequence — Step-by-step construction sequence.
Safety controls — HSE risk controls and PPE.
Environmental controls — Environmental mitigation measures.
QA/QC — Quality inspection and test requirements.
ITP — Inspection and Test Plan table (has its own page).
Attachments — Referenced drawings and documentation.

Why this method statement is used

This method statement is used to define and communicate the approved procedure for carrying out method statement: spray-applied cementitious fireproofing (sfrm) to structural steel on site. It ensures the work is planned in advance, the correct resources and controls are in place, and all personnel understand responsibilities, sequence, quality requirements, and safety controls before work begins. It aligns site execution with the documented scope and acceptance expectations.

Who uses this method statement

This method statement is used by contractors, site supervisors, project engineers, QA/QC engineers, HSE officers, consultants, and client representatives. It serves as a shared reference for planning, execution, supervision, inspection, and approval of the activity on site.

When it is prepared and submitted

The method statement is prepared before the work activity starts and submitted as part of the pre-construction documentation package for review and approval.

Who reviews or approves it

The method statement is usually submitted to the client representative, consultant, resident engineer, or project management consultant for review and approval before the work commences.

Important approval note

This method statement is an AI-assisted editable starting point, not a pre-approved document. Before use on any project, all content must be reviewed and approved by the relevant parties (superintendent, principal contractor, or client representative) in accordance with your contract and project quality plan.

For example: if your specification requires a departure from a referenced standard, that departure must be documented and approved separately — this method statement will not capture that automatically. Always verify against your applicable drawings, specifications, and regulatory requirements.

Method statement content

Scope

Overview

This method statement covers supply, preparation, masking, mixing, spray application, curing, repair, and quality control of spray-applied cementitious fire-resistive material (SFRM) to structural steel columns, beams, and connections. It includes work on bare or primed steel, thickness control as per the required fire-resistance rating and section factor, adhesion/cohesion testing, density checks, curing and protection, waste management, QA/QC, and final acceptance.

Extent of Work

Structural elements: columns, beams, braces, and connections as shown on drawings.
Fire ratings: 1–4 hours [Verify per project specifications].
Substrates: bare steel or steel with approved compatible primer.
Interfaces: firestopping, MEP supports, anchors, and adjacent finishes to be protected.

Exclusions

Intumescent coatings (separate method if required).
Acoustic/thermal insulation unrelated to fireproofing.
Structural steel remedial works beyond minor cleaning/rust removal.

Objectives

Achieve required fire-resistance rating using the specified SFRM and applicable UL/EN design.
Meet quantitative tolerances for thickness, adhesion/cohesion, and density.
Deliver compliant records and approvals for handover.

References

Document Type	Reference / Number	Notes
Standard	ASTM E605/E605M
Standard	ASTM E736/E736M
Standard	UL 263 / ASTM E119	Use applicable UL Design Number(s) for members [Verify per design]
Reference	UL Online Certifications Directory	Use project-approved design listings
Standard	BS EN 13381-4/-8 [Verify applicability]	Use where Eurocode/EN route is adopted
Standard	SSPC-SP 2 / SP 3; SSPC-PA 1	Primer compatibility to be confirmed in writing by SFRM manufacturer
Standard	AISC 360	For structural acceptance prior to SFRM
Manual	Approved SFRM Manufacturer	Pre-application conference with manufacturer’s representative

Responsibilities

Role	Responsibility	Name / Party
PM	Ensure method and ITP approved; coordinate with trades	Main Contractor
Supervisor	Daily checks on substrate, masking, mix logs, environmental limits	Specialist Subcontractor
QA/QC	Verify hold/witness points; coordinate independent tests	Main Contractor
HSE	Ensure controls for silica dust, MEWP, hot works isolation, alarms masking	Main Contractor
Tech Rep	Issue compatibility letter; sign-off on mock-up	Manufacturer
Lab	Witness/perform tests, issue certified reports	Approved Laboratory
Engineer	Approve ITP, mock-up, and final works	Engineer/Client

Resources

Resource Type	Description	Quantity
Manpower	Skilled nozzlemen for SFRM	As scheduled
Manpower	Controls water ratio, mixing time, pump speed	1 per pump
Manpower	Masking, material handling, housekeeping	2–6 [Verify]
Manpower	Access provision and safe operation	As required

Materials

Material	Specification / Grade	Quantity	Remarks
SFRM		Per BOQ + 5% waste [Verify]
Bonding agent		As needed
Primer
Water		Per mix ratio
Masking		As required

Equipment

Equipment	Capacity / Type	Quantity	Inspection Required
Mixer/Pump	Output 20–60 L/min [Verify]	1–2 units [Verify]	Yes
Compressor	5–10 m³/min at 0.5–0.7 MPa [Verify]	1	Yes
Spray set		As required	Yes
Gauges		2+	Yes
Pull tester		1	Yes
Core kit + oven		As needed	Yes
Scaffold/MEWP		As needed	Yes
HEPA vacs		As needed	Yes

Prerequisites

Approvals and Submittals

Product data sheets, SDS, UL/EN design listings, primer compatibility letter, method statement, and ITP approved.
Mix design and water ratio per manufacturer; equipment calibration certificates available.

Site Readiness

Structural steel inspected and released by Engineer; all welding/bolting complete; surfaces accessible.
Ambient/substrate conditions within manufacturer limits: typically 4–43°C, RH < 85%, no condensation (substrate ≥ 3°C above dew point) [Verify per TDS].
Power, water, compressed air available and safe; lighting ≥ 200 lux at workface [Verify].

Mock-Up

Construct representative mock-up (min 1.0 m x 1.0 m including primed member) to demonstrate finish, thickness control, and testing. Obtain written approval prior to production.

Interfaces/Protection

Mask adjacent finishes, equipment, and fire detectors; isolate/suppress alarms as approved by Client/Facility [Verify per HSE plan].
Access (scaffold/MEWP) inspected and tagged valid for use.

Training & Permits

Applicators trained/experienced on specified SFRM; toolbox talk completed.
Permits in place: Hot work isolation (if any), MEWP operation, working at height, and dust/ventilation controls [Verify per local regulations].

Method Sequence

Step	Activity	Description	Responsibility	Inspection / Hold Point
1	Pre-Start Coordination and Layout	Review drawings/UL-EN designs; identify members, W/D (Hp/A) ratios, required thickness; mark member IDs and thickness targets.	Fireproofing Supervisor / QA/QC	Hold Point HP-0: Pre-start meeting sign-off
2	Substrate Inspection & Prep	Check steel is clean, dry, free of oil, laitance, loose rust/scale; remove contaminants (SSPC-SP 2/3). Treat local rust. Ensure primer is fully cured and sound; verify DFT if required.	QA/QC Engineer / Supervisor	Hold Point HP-1: Substrate and primer readiness
3	Primer Compatibility Confirmation	Obtain written confirmation from SFRM manufacturer for existing/shop primer. If required, apply approved bonding agent per TDS and allow to cure.	Manufacturer Rep / Supervisor	Hold Point HP-2: Compatibility letter/bonding agent approval
4	Masking and Protection	Install plastic sheeting, tapes, boards to protect adjacent finishes, floors, equipment, and MEP. Bag/cover detectors or isolate alarms as approved.	Supervisor / HSE	Witness Point W-1: Protection in place
5	Mixing and Pump Setup	Set calibrated water meter; mix SFRM per bag manufacturer ratio and time (e.g., 2.5–4.5 L/kg; mix 2–4 min) [Verify per product]. Avoid over-watering. Maintain continuous feed to pump; perform slump/consistency check if required by TDS.	Pump Operator	Witness Point W-2: First batch verification
6	Spray Application - First Pass	Hold nozzle 0.6–1.0 m from substrate; apply at 90° to surface; build to 10–15 mm per pass [Verify]. Encapsulate flanges and webs evenly, starting with flanges’ edges then webs to reduce rebound.	Applicator	In-process check by Supervisor
7	Interpass Set and Additional Coats	Allow initial set per TDS (typically 30–90 min) before subsequent passes. Lightly score surface if required to enhance key between coats. Continue until near-target build is achieved.	Applicator/Supervisor	In-process
8	Detailing at Connections and Penetrations	Hand-apply at bolts, stiffeners, hangers; ensure full encapsulation without bridging. Maintain specified clearances for future MEP works.	Applicator	In-process
9	Initial Thickness Checks	After sufficient set, measure thickness using pin gauge at grid spacing (typ. min 1 reading per m² or per member face; ≥ 10 readings per member set) [Verify]. Adjust with additional spray where deficient.	QA/QC / Supervisor	Witness Point W-3: First area thickness sampling
10	Curing and Protection	Protect from impact, vibration, rain, water spray, and freezing for minimum 24–72 h [Verify]. Provide ventilation to aid drying; prevent rapid desiccation. Maintain temperature and RH within TDS limits.	Supervisor	Routine HSE/QA checks
11	Adhesion/Cohesion Testing	Conduct ASTM E736 tests on set material using 50 mm dollies. Frequency: min 1 test per 930 m² (10,000 ft²) per floor/area per substrate/primer condition per day [Verify]. Additional tests at changes in primer/product/environment.	QA/QC / Independent Lab	Hold Point HP-3: Adhesion test witnessing
12	Density Sampling	Extract field cores for density per ASTM E605. Frequency: min 1 sample per 465 m² (5,000 ft²) per product per day or as specified [Verify]. Oven-dry to constant mass at 110 ± 5°C.	Independent Lab / QA/QC	Witness Point W-4: Core extraction
13	Repairs and Deficiency Closure	Address thin areas, damage, or test failures by re-prep, re-application, and re-testing as required. Feather and blend repairs.	Supervisor / QA/QC	Follow-up inspections
14	Final Inspection and Acceptance	Complete 100% visual check; verify thickness dataset coverage, adhesion/density tests, curing complete, protection removed, area cleaned. Submit as-built thickness maps and test certificates.	QA/QC / Engineer	Hold Point HP-4: Final acceptance inspection

Health, Safety and Environment (HSE) - Safety Controls

Task-Specific Hazards and Controls

Hazard: Working at height (scaffolds/MEWPs)
Likely consequence: Falls causing serious injury/fatality
Engineering/procedural control: Certified scaffold with guardrails; MEWP with pre-use checks and exclusion zone; maintain 3-point contact and platform load limits; tie-off where required; rescue plan
Required PPE: Full body harness with lanyard (in MEWP if manufacturer requires), hard hat, safety boots
Collective preventive measure: Edge protection, toe boards, properly decked platforms
Inspection/permit/supervision: Daily scaffold tag checks by competent person; MEWP operator license; PTW for MEWP; supervisor oversight
Hazard: Respirable dust (cementitious product, possible crystalline silica)
Likely consequence: Respiratory irritation, silicosis (chronic), eye injury
Engineering/procedural control: Use pre-bagged materials; mix in enclosed/ventilated area; local exhaust ventilation; wet methods to suppress dust; HEPA vacuums; minimize drop heights; sealed waste bags
Required PPE: Tight-fitting RPE (P100/FFP3), goggles/face shield, gloves
Collective preventive measure: Dust screens around mixing; directional ventilation
Inspection/permit/supervision: Air monitoring if required; RPE fit-test records; [Verify per project HSE plan and local regulations]
Hazard: Caustic exposure (wet cement)
Likely consequence: Skin/eye burns, dermatitis
Engineering/procedural control: Avoid skin contact; use mixing guards; provide eyewash and clean water; immediate decontamination procedure
Required PPE: Alkali-resistant gloves, long sleeves, goggles/face shield, impervious apron at mixing
Collective preventive measure: Spill kits and wash stations in mixing zone
Inspection/permit/supervision: HSE checks; SDS available
Hazard: Compressed air and pressurized hoses
Likely consequence: Hose whip, injection injury, impact
Engineering/procedural control: Secure hose couplings with safety clips/whips; pressure within OEM limits; depressurize before maintenance
Required PPE: Gloves, eye/face protection, safety boots
Collective preventive measure: Barriers around pump/hoses; clear routing to avoid trip hazards
Inspection/permit/supervision: Pre-start equipment checklist; competent operator
Hazard: Manual handling of 20–30 kg bags
Likely consequence: Strains, musculoskeletal injury
Engineering/procedural control: Use mechanical aids, team lifts, staging at waist height; rotate tasks
Required PPE: Back support as needed, gloves, boots
Collective preventive measure: Palletized deliveries close to point-of-use
Inspection/permit/supervision: Manual handling training verification
Hazard: Overspray onto live equipment/fire detectors
Likely consequence: Damage, false alarms, service disruption
Engineering/procedural control: Masking and isolation per permit; protective enclosures; signage
Required PPE: Standard site PPE plus goggles during spraying
Collective preventive measure: Area segregation and covers
Inspection/permit/supervision: Permit/authorization from facility; pre- and post-works checks
Hazard: Noise from compressor/pumps
Likely consequence: Hearing damage
Engineering/procedural control: Use quieter equipment; position away from personnel; limit exposure time
Required PPE: Hearing protection (earplugs/muffs)
Collective preventive measure: Noise barriers where feasible
Inspection/permit/supervision: Noise surveys where required
Hazard: Fire alarm isolation or hot works nearby
Likely consequence: Uncontrolled fire risk or missed detection
Engineering/procedural control: Approved isolation plan and fire watch; no ignition sources near dust clouds
Required PPE: Standard PPE
Collective preventive measure: Temporary detection heads/covers; fire extinguishers at workface
Inspection/permit/supervision: Permit to work; coordination with facility; [Verify per local regulations]
Hazard: Falling objects (tools/materials from height)
Likely consequence: Head injury to people below
Engineering/procedural control: Tool lanyards, debris nets, exclusion zones below work area
Required PPE: Hard hats, safety footwear
Collective preventive measure: Barricading and spotters
Inspection/permit/supervision: Supervisor to enforce exclusion zone

Emergency Preparedness

First aid kit, eyewash station at mixing zone; spill kits for slurry.
Emergency contacts posted; rescue plan for MEWP/scaffold incidents.
Fire extinguishers (ABC) within 15 m of workface [Verify per HSE plan].

Environmental Controls

Controls

Dust and Overspray
Install temporary enclosures and dust screens around mixing and spray zones.
Use LEV/HEPA extraction; avoid spraying in high winds; schedule during low-traffic periods.
Cover drains and sensitive equipment; remove masking carefully to prevent debris release.
Washout/Slurry and Water Management
Establish lined, bunded mixing/washout area; collect water and allow solids to settle.
Adjust pH before discharge; dispose via licensed waste contractor [Verify per local regulations].
Waste Segregation
Segregate clean empty bags for recycling where permitted; double-bag contaminated waste.
Maintain waste transfer notes and manifests.
Noise and Vibration
Position compressors away from receptors; use acoustic shields where needed; restrict hours per permit.
Materials and Storage
Store SFRM bags off ground, dry, covered; rotate stock (FIFO); protect from moisture ingress.
Spill Prevention
Keep spill kits at mixing station; immediate containment and cleanup of leaks.
Energy and Air
Shut down idle equipment; maintain engines to reduce emissions; no unnecessary idling.
Monitoring
Environmental log: temperature, RH, wind (if external), dust observations, noise complaints; corrective actions recorded.

Quality Assurance and Quality Control (QA/QC)

QA/QC Plan

Submittals: Product approvals, UL/EN design numbers, primer compatibility letter, method statement, ITP, calibration certificates.
Mock-Up: Demonstrate finish, build strategy, and pass adhesion/density benchmarks prior to production.
Identification/Traceability: Record bag batch/lot numbers per work area and date.

Measurements and Frequencies

Thickness (ASTM E605 field): Grid-based checks; typical minimum 1 reading per m² or per member face with ≥10 readings per member group; increase frequency at complex connections [Verify per spec].
Adhesion/Cohesion (ASTM E736): Min 1 test per 930 m² (10,000 ft²) per floor/area per substrate condition per day; additional after failures/changes [Verify].
Density (ASTM E605): Min 1 sample per 465 m² (5,000 ft²) per product per day [Verify].
Environmental: Record ambient and substrate temperature, RH, and dew point each shift and when conditions change.

Acceptance Criteria

Thickness: Average thickness per area/member ≥ specified by UL/EN design for the W/D (Hp/A); no single reading < 85–90% of specified [Verify per project].
Adhesion/Cohesion: ≥ value specified by manufacturer/project. Typical benchmark ≥ 150 psf (≈7.2 kPa). Failure mode preferably cohesive within SFRM [Verify].
Density: Within product-specified range (e.g., 240–640 kg/m³) and within tolerance (commonly ±15%) [Verify].
Visual: Uniform appearance; no delamination, cracking, spalls, voids, or uncoated areas.

Documentation

Daily reports, mixing logs (water ratio/time), batch numbers, calibration records, IRs, test reports, as-built thickness maps, NCR/CAR and closures.
Handover dossier: Approved ITP, test certificates, compatibility letters, UL/EN design schedules, O&M instructions.

Attachments

Approved product technical data sheets (TDS) and Safety Data Sheets (SDS)
UL/EN design listings with required thickness vs W/D (Hp/A)
Primer compatibility letter from SFRM manufacturer
Mix logs, calibration certificates (pump, water meter, gauges, pull tester, oven)
Environmental monitoring logs and dew point calculations
Mock-up approvals and test reports (ASTM E605/E736)
Daily inspection reports, thickness maps, and photo records
NCR/CAR (if any) and closeout evidence
Training, licenses, and permits (MEWP, scaffold tags, PTWs)
Handover package index and sign-offs

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ITP preview

The first inspection activities from the linked ITP for Method Statement: Spray-Applied Cementitious Fireproofing (SFRM) to Structural Steel:

Activity	Inspection / Test	Acceptance Criteria	Responsibility	Record
Pre-start Review and Design Thickness Schedule	Document review of UL/EN design mapping to members and required thickness	Schedule approved; W/D (Hp/A) basis recorded [Verify]	Contractor QA/QC / Engineer	Approved schedule, minutes
Substrate and Primer Readiness (HP-1)	Visual cleanliness; dryness; primer condition; dew point check	Clean, dry, sound; Tsubstrate ≥ Tdew+3°C [Verify]	QA/QC / Engineer	IR with photos
Primer Compatibility/Bonding Agent (HP-2)	Review compatibility letter; verify bonding agent application (if required)	Written confirmation; bonding agent per TDS	Manufacturer Rep / QA/QC / Engineer	Letter, TDS, application log

Showing 3 of 10 inspection activities. View full ITP →

Related Inspection and Test Plan

An Inspection and Test Plan (ITP) is available for Method Statement: Spray-Applied Cementitious Fireproofing (SFRM) to Structural Steel. The ITP defines the inspection activities, acceptance criteria, hold and witness points, responsible parties, and records required to verify the work described in this method statement.

View the Method Statement: Spray-Applied Cementitious Fireproofing (SFRM) to Structural Steel ITP →

Frequently asked questions