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The Trafalgar FireBOX™ range includes: • FyreBOX™ Slab-Mounted • FyreBOX™ Cast-In • FyreBOX™ Maxi • FyreBOX™ Mini

FyreBOX™ CAST-IN

07052020

Changing the way we build to improve fire safety.

Part of the fire stopping family of products

FYREBOX and FIREBOX are trademarks of Fire Containment Pty Ltd

fyrebox.com.au | firebox.com.au 1800 888 714

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Trafalgar is proud to introduce FireBOX™, a revolutionary new fire stopping

solution. FyreBOX™ CAST-IN allows for multiple and mixed services to pass through it,

and in close vicinity to each other, with proven fire testing eliminating the need for

200mm separation between adjacent services. It also allows for cable trays to pass

directly through it.

Many builders have learnt the hard way, by getting called back under warranty to redo

poorly designed or installed passive fire protection. Trafalgar has changed the status

quo; we have listened and delivered a new family of engineered products to make

installation and ongoing certification more robust.

FYREBOX and FIREBOX are trademarks of Trafalgar Group Pty Ltd

Take Back Full Control The use of FireBOX™ allows a completely different

approach to who does the fire stopping, and why

on your projects.

You can now plan ahead for services and avoid

costly fire stopping mistakes by using the

FireBOX™.

A little bit of forward planning and you can rest

easy knowing that your fire stopping is sound and

that any call backs can be quickly dealt with and

will not be costly.

FyreBOX™ CAST-IN

Product Overview



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Non-compliant Installation Compliant Installation using FyreBOX™ Cast-In

Product Overview FyreBOX™

CAST-IN

FireBOX™ is Fast,

Clean and Easy.




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• FireBOX™ helps builders and service trades to organise their fire stopping.

• FireBOX™ reduces the overall installation area for service penetrations.

• FireBOX™ avoids the need for fire stopping of multiple openings.

• FireBOX™ makes it easier to know where to route services.

• FireBOX™ is ideal for new buildings, and is NCC 2022 ready

• FyreBOX™ CAST-IN comes complete with a galvanised steel lid to protect the inside

during installation and casting.

• FireBOX™ simplifies and reduces construction and maintenance costs over the life of

the building.

• FyreBOX™ CAST-IN can be custom made to suit multiple slab thicknesses.

• FyreBOX™ CAST-IN has been fire tested empty and all the way up to completely full.

• FyreBOX™ CAST-IN is 125mm wide making them suitable for most services and can be

as long as 1250mm allowing for large service runs.

Key Features & Benefits

AS1851-inspection for fire services now means that a building and its so called passive

fire protection systems will be inspected annually. The Trafalgar FireBOX™ system is

changing the way builders build and allowing for easier compliant fire stopping.

FyreBOX™ CAST-IN

Product Overview




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FyreBOX™ CAST-IN


PRODUCT DESCRIPTION

Fire Rating Up to -/240/240 – Please consult the FRL tables on page 8-9 to confirm suitability for your application.

Testing The FyreBOX™ Cast-In is fire tested and fully approved to AS1530.4-2014 and AS4072.1 for use with a multitude of services.

Body Constructed from mild steel and is orange for ease of identification.

Galvanised steel lid.

Maintenance Annual inspections as per AS1851.

Application Tested and approved for the following services:

• Electrical, data, communication cables.

• Steel pipes. • Insulated copper pipes. • Plastic conduits. • PEX pipes • Any configuration of the above.

Mixed services can run through FyreBOX™ Cast-In.

Specifications Cast a FyreBOX™ Cast-In into position marked on the floor slab drawing. All relevant trades are to route services which penetrate the floor slab through the FyreBOX™.

Technical Specifications

FRL -/120/0 Due to 100mm copper pipe

FRL -/120/120 with TWrap or FyreWrap Insulation

System



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The FireBOX™ system allows building designers

and service consultants to identify the required

location for services and specify Trafalgar

FyreBOX™ CAST-IN. For BIM models please

contact [email protected].

This ensures that all services are adequately

fire stopped. The best part is that the

FireBOX™ is a permanent system and will not

require fire stopping again for the life of the

building.

NOTE: The FyreBOX™ Cast-In standard depth is 380mm. The FyreBOX™ Cast-In can be manufactured with varying depths based on slab thickness (FyreBOX™ depth must be slab depth +50mm minimum). Contact Trafalgar to discuss your specific requirements.

** - Refer to FRL tables below for specifics on services, FRL’s, and wrapping requirements


FyreBOX™ CAST-IN Code Size (mm)

L x W x D

Standard Width

Fire Rating/s

Minimum Floor Slab Thickness

FYREBOX-CI-350

350 x 125 x 380

125mm

-/60/60 -/90/90

-/120/120 -/180/120 -/180/180 -/240/120 -/240/240

**

At least 120mm

FYREBOX-CI-650

650 x 125 x 380

FYREBOX-CI-1100

1100 x 125 x 380

FYREBOX-CI-CUSTOM

XXX x 125 x Slab depth + 50mm

(Any length up to 1250)

Ordering Information

Length

Depth

Width

FyreBOX™ CAST-IN



of 16 FYREBOX and FIREBOX are trademarks of Trafalgar Group Pty Ltd

FyreBOX™ CAST-IN

Pre-Installation check: Approved services and fire barriers

Concrete floor slabs – Minimum 120mm

FyreBOX™ Maxi and Mini installed in concrete floor slabs (120mm thickness) Service

type Service specification FRL (no wrap required)

FRL with Twrap/FyreWrap

Plastic pipes

Rigid or flexible uPVC conduits up to 32mm OD (with or without cables) -/120/60 -/120/120

PEX pipes up to 32mm OD -/120/- -/120/120 PEX-al-PEX pipes up to 32mm OD -/120/- -/120/120

uPVC sprinkler pipes up to 80mm OD -/120/- -/120/120

Bare metal pipes

Copper pipes up to 50mm OD -/120/- -/120/120 Copper pipes 50 to 100mm OD -/120/- -/120/120**

Steel pipes up to 50mm OD -/120/- -/120/120 Steel pipes 50 to 100mm OD -/120/- -/120/120**

Insulated metal pipes

Copper pipes up to 50mm OD with FR insulation -/120/60 -/120/120 Stainless steel pipes up to 50mm OD with EPS or PE insulation

(replaced with Rockwool through Fyrebox) -/120/60 -/120/120

Paircoil pipes up to 9.5 and 19mm OD with PE insulation up to 13mm thickness

-/120/60 -/120/120

Paircoil pipes up to 9.5 and 19mm OD with FR insulation up to 20mm thickness

-/120/60 -/120/120

Power cables All power cables -/120/30 -/120/120*

Comms cables All comms cables -/120/60 -/120/120

Note: All systems to use minimum 450mm TWrap / FyreWrap to the top side of the floor slab only as indicated * Large single-core cables require 600mm of TWrap / FyreWrap, all other power cables require 450mm on the top side only ** These systems require additional wrap – Please see the installation options on page 15 for details on how to treat large pipes

FRL Details



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FyreBOX™ CAST-IN

FRL Details


Pre-Installation check: Approved services and fire barriers

Concrete floor slabs – Minimum 180mm

FyreBOX™ Maxi and Mini installed in concrete floor slabs (180mm thickness) Service

type Service specification FRL (no wrap required)

FRL with Twrap/FyreWrap

Insulated metal pipes

Stainless steel pipes up to 50mm OD with EPS or PE insulation (replaced with Rockwool through Fyrebox) -/240/60 -/240/240

Power cables 2x 19mm 3C+E power cables -/240/60 -/240/120

Comms cables All comms cables -/240/60 -/240/120

Note: All systems to use minimum 450mm TWrap / FyreWrap to the top side of the floor only slab as indicated

FyreBOX Cast-in after a 4 hour test in accordance with AS1530.4-2014



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1. Position the FyreBOX™ Cast-In in the desired penetration position, and then fix it to the timber formwork.

2. Ensure the galvanised steel lid is on the FyreBOX™ Cast-In and then pour the concrete to the specified depth and allow to cure.

3. After the concrete has cured, remove the

timber formwork from the other side of the slab.

4. Remove the steel lid from the FyreBOX™ Cast-In and dispose. Remove the foam plugs from both ends and put in a safe location for subsequent use.

5. Apply a small bead of FyreFLEX sealant to the

perimeter of the casing

Note: Sealant not required for boxes 350mm wide or under

Please view our installation video. Go to www.youtube.com.au and search for Trafalgar TV.

FyreBOX™ CAST-IN

Installation Overview


INSTALLATION OVERVIEW

http://www.youtube.com.au/



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FyreBOX™ CAST-IN

Installation Overview

6. Install services through the FyreBOX™ Cast-In as required, ensuring the services are approved for use. Refer to FRL details section of this manual for details.

7. Re-fit the foam end plug on the top side only. Cut the foam to suit the approximate service locations and undersize any holes to ensure a tight fit.

8. Ensure no visible gaps are present, and for any small openings around the services apply a small bead of FyreFLEX or FyrePEX HP sealant Note: For documentation purposes Trafalgar recommend taking photographs of the installation at this stage to demonstrate correct installation.

9. If required, fit TWrap or FyreWrap to achieve full insulation.

Ensure overlaps are at least 75mm and the wrap is secured with 3x stainless steel cable ties as shown.

10. Take final as-installed photographs and enter the FyreBOX Cast-In into the site penetration register.

Please view our installation video. Go to www.youtube.com.au and search for Trafalgar TV.


http://www.youtube.com.au/



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FyreBOX™ CAST-IN

Installation Options


Because of the significant amount of testing Trafalgar have undertaken on the FyreBOX™ Cast-In systems, many alternate installation options are available for unique site requirements. Alternate installation details include:

• FyreBOX™ systems in close proximity

• Slabs greater than 300mm thickness

• Large metal pipes

• Retrofitting Cast-In boxes – FyreBOX™ Cast-In in FyreSET mortar Fire testing of Trafalgar products, and the FireBOX™ family is always ongoing – If your application is not covered by this product manual please call our technical team.



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FyreBOX™ CAST-IN



FYREBOX™ SYSTEMS IN CLOSE PROXIMITY Ideal for cluttered risers and/or large service runs, FyreBOX™ Cast-In can be installed within 100mm of any other FyreBOX™, allowing for safe, compliant and simple firestopping of complex penetrations.

Fast. Clean. Easy.



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FyreBOX™ CAST-IN



SLABS GREATER THAN 300MM THICKNESS Suitable for use in any slab thickness, Trafalgar can custom-make your FyreBOX™ Cast-In in our South Granville, NSW factory. Proudly Australian made and here to support you.

Fast. Clean. Easy.



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FyreBOX™ CAST-IN



LARGE METAL PIPES Tested with 100mm copper and steel pipes, FyreBOX™ Cast-In provides the most comprehensive and reliable method of firestopping difficult penetrations. Pipes over 50mm require a longer length of wrap for insulation performance, but can easily be installed in FyreBOX Cast-In for a -/120/120 FRL. Others claim it – We burn it.

Fast. Clean. Easy.



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FyreBOX™ CAST-IN

System Selector


FYREBOX™ Maxi

FYREBOX™ Slab-Mounted

FYREBOX™ Cast-in

NEW project – walls and floors yet to be

constructed.

Walls/floors with services installed, or about to be installed.

Floor New Residential Walls

Wall/floor opening size

< 150mm

Wall/floor opening size

> 150mm

FYREBOX™ Mini

System Selector

Not sure on which FIREBOX™ you require. Don’t worry, review our System Selector for assistance or call the Trafalgar team on 1800 888 714.



of 16 FYREBOX and FIREBOX are trademarks of Trafalgar Group Pty Ltd

FyreBOX™ CAST-IN

Trafalgar has developed a range of installation videos to assist our customers. To view these step by step install videos please go to Trafalgar TV our YouTube Channel.

Subscribe and you will be notified when new videos are uploaded.

Trafalgar reserves the right to change specifications without notice. Please check with your supplier at the time of order. The information contained in this brochure was correct at the time of print. E&OE. Published 30.07.2019

System Selector

System FyreBOX™ Slab-Mounted

FyreBOX™ Maxi

FyreBOX™ Mini

FyreBOX™ Cast-In

Fire Barrier

Plasterboard, Hebel, Walsc, SpeedPanel,

Maxilite, and masonry/concrete

walls

Plasterboard, Hebel, Walsc, SpeedPanel, Maxilite, and

masonry/concrete walls and concrete slabs

Concrete Slabs FyreSET Mortar

Installation Prior to Fire Barrier Construction

Cutting required During wall construction Pre-formed holes or core holes None

Power Cables Data Cables

Cable Trays

Metal Pipes with/without

insulation

CPVC pipes

PVC pipes Floors only

PEX/Gas PEX

System Selector Continued

For full FRL details please consult the relevant technical guide or contact Trafalgar. Fire testing of Trafalgar products is always ongoing.

Please also review our wide family of products, offering fire containment solutions for every application – Fyre Fire Stopping Range

https://www.youtube.com/channel/UCBz-5C9dtI-1_z0A6JudfbA

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https://tfire.com.au/catalogue/cat/FYRE-Fire-Stopping-Products

https://tfire.com.au/catalogue/cat/FYRE-Fire-Stopping-Products

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