Care your employee,real estate and job with Firesafe“Flame Observation Technology”

Property Insurer Fire CertificationRequirements

Introduction 1

Insurance Certification 2

Fire Test 4

Facts and confirmed research 7

Myths and Misinformation 8

Case study 10

Firesafe at a glance 12

Kingspan are world leaders in the research, development

and testing of fire engineered insurer approved firesafe

roof, wall, facade and temperature controlled (chill and

cold store) systems. This work has resulted in the

development and application of fire engineered

technologies which provide firesafe systems for building

owners, occupiers and tenants, enhancing property and

business risk protection.

Kingspan’s firesafe solutions are based upon Factory

Mutual Global (FM) and the Loss Prevention Certification

Board’s (LPCB) rigorous fire test and accreditation

methods. FM and LPCB systems are widely recognized

by investors, property insurers, designers and

constructors for their superior fire engineered performance

thus reducing fire risks.

Kingspan believes that the only way to test any cladding

system is to perform a realistic scale test on the composite

product incorporating realistic joint details and fixings.

The new Euroclass Reaction to Fire Tests does not fully

assess panel performance and should not be taken in

isolation. Large scale fire tests such as those carried out

by FM Global and LPCB provide a better indicator of

how panels will perform in a real fire situation.

Introduction

Contents

Insurance Certification...

Factory Mutual Global (FM)Approval Requirements

FM Global (FM), formally known as Factory Mutual, hasa severe test standard for assessing reaction to fire. This teststandard is FMRC 4880 (1994) Approval requirements forClass 1 fire classification.

Achievement of Class 1 is dependent on performance in anumber of tests that include –

• ASTM E84 Surface Burning Characteristics• ASTM D482 Ignition Residue tests• ASTM E711 Oxygen Bomb tests• UBC 26-3 Room Test• FMRC Room Corner Test (25/50ft test)

LPCBThe loss Prevention CertificationBoard (LPCB) provides stringentlarge scale fire testing,certification, approval proceduresand guidance contained in theLPCB Design Guide for the FireProtection of Buildings. Theserequire that the approvedsystems/equipment arefit-for-purpose when needed.

The building fabric is an important part of any insuranceassessment. Choice of an FM approved panel system oran appropriate grade of LPCB approved panel will lead to -

No Rate of ConsiderationNo Additional Excess

Adana

Limak Limkon

Project Name :Panel Types :

Usage

Limak LimkonKS 103 FMF MegalambriKS 100 FPR PrestigepanelKS 110 FTF IzocoldFruid Concentrade Facility

Insurer Certification Requirements

FM 50ft Room Corner Test

The images on these 2 pages show a sequence from ignitionto extinguishment of 200mm thick Kingspan IPN panels.The fire load consists of 345kg red oak pallets.

The key pass-fail criteria is that there is no lateral fire spread tothe edge of the enclosure and no ignition of the ceiling. TheKingspan panels are well within these limits proving that thepanels do not promote the spread of fire. As a result of this test,and other large scale tests Kingspan wall, roof and ceiling panelsare approved by FM Global.

The FM Global FMRC 4880 maximum 50 ft (15.24 metres) heightwall test is very severe. Two walls 15.24 m high with a smallceiling are lined with panels and a large fire source (345kg drytimber) is positioned in the corner. To achieve approval there hasto be no flame spread or fire propagation to the extremities ofthe panel construction. Kingspan FM approved panels are wellwithin these limits with no flame spread away from the fire source.

Fire is contained in the room cornerno evidence of fire propagation

Panels removed after LPC test show no spread of flame

LPS 1181 Fire Tests

Large Scale Fire TestingLPS 1181 Test

The key parameters of the test include:• Fully Developed fire -1 mega watt fire load.• Max temp > 1,000˚C at internal surface.• LPS 1181 test designed to assess flarme spread, ignition

and promote flash over conditions.

Kingspan FireSafe Results

• Effect at 1,000 ˚C internal surface temperature.• Stable protective char formed.• Char/core expands to fill any gap between facings,

consequently no voids.• Fire rated isophenic core.

70% unaffected, 30% char at 1,000 ˚C• No spread of flame, flashover or

fire travel within the core between the facings.• At high temperatures greater

than 300 ˚C protective char forms.• Panels are unaffected away from main fire source.

Facts and Confirmed Research

• The gases given off when isophenic foam burms areless toxic than those given off by conventional buildingmaterials (e.g. wood)

• When used as roof cladding, the sandwich panels resistthe spread of fire and reduce radiant heat

• The additional fire load caused by isophenic panelsvaries between 3 and 6 kWh/m2 and therefore has verylittle effect on a fire. This very low value results fromthe low density of the insulating foam core which isapproximately 40 kg/m3

• The results from the standardised tests used todetermine combustibility are confirmed completely bythe behaviour of the panels in practice

Conclusion...The behaviour of KINGSPAN insulated roof and wallpanels in a fire is similar to that of other fire-resistantbuilding materials.

With respect to current fire regulations and the need tobuild passive fire protection into a structure, insulatedisophenic panel systems are amongst the safest provenbuilding methods.

Although the rigid isophenic used in the panels isunsurpassed in its thermal insulating properties, it isbasically combustable, like all organic substances.

But the historical fire performance and insurance lossstatistics relating to the use of Kingspan isophenic (IPN)panels in the external envelope has been excellent.

There is no evidence whatsoever to suggest that Kingspanpanel systems are not fit-for- purpose and there is nolink with higher insurer losses. This is proven by detailedinsurer loss statistics and case studies on fires in buildingsclad with such panels.

The following findings can be summarized from theresearch carried out on many real fires where Kingspaninsulated roof and wall systems were in use:

• The panels do not contribute to a fire. they are onlydamaged in the immediate area of the fire andself-extinguish after the fire load has gone

• By forming a protective char layer, the fire is starvedof oxygen between the metallic skins of the panel.The panels are thus self-extinguishing and do notcontribute to a fire.

• Thermoset rigid isophenic (IPN) does not melt or dripwhen exposed to fire. Thus, the danger of ignitingsecondary fires does not arise.

The real issue is not directly related to the combustibilityof the panel system core - all have combustible elements.The real issue is related to how a specific system willperform in a real fire scenario and whether it acts asnoncombustible building element by not contributing to fire.

A propane torch reduces polystyrene to flammable gas and liquid in seconds

Myths & Misinformation

Combustibility ofinstalled panel systems...

In recent years, huge confusion has been caused by panelmanufacturers and their suppliers making claim andcounter claim about the non-combustibility or otherwiseof their own and their competitors panel systems.

ABI Definitions of Construction 2003(ABI - Association of British Insurers)The following table outlines the ABI´sDefinitions of Construction

Combustibility ofReal-Life Panel Installations...

The reality is that all panel systems have varying levelsof combustibility because all contain combustiblematerials. The only reliable way of assessing panel systemcombustibility is to base a judgement on testing theentire system. Tests and standards such as LPS 1181,LPS 1208 and FM 4880 are ideal in this respect. Thevarying levels and grades of performance defined bythese tests allow the specific panel system performanceto be matched to the specific risk.

Ignitability of Polystyrene...Polystyrene is a thermoplastic – this means that heat will cause the material to melt and form a liquid. This liquid is highlyflammable and easily ignites. This performance is in stark contrast to isophenic a thermosetting material, which forms astrong carbonaceous char protecting the core from further attack.

FIRE RESISTING All elements of construction(including floors) to benoncombustible and achieveat least 90 minutes fire resistance

Definition Description

NON COMBUSTIBLE All elements of constructionto be non-combustible OR approvedto LPS 1181 INCLUDES KINGSPANFIRESAFE IPN

PARTLY COMBUSTIBLE Any building having from 10% up to35% construction elements ofcombustible construction.

COMBUSTIBLE Any building having between 35%and 70% of combustible materialsin the elements of construction.

HIGHLY COMBUSTIBLE Any building having over 70%of combustible materials intheir element of construction

Myths & MisinformationIgnitability of Kingspan Fire Rated IPN

One concern raised by insurers is the potential for exposedinsulation in ‘real’ situations. The reality is that any insulationpanel system is likely to be damaged or modified after installationand this may lead to exposure of the core – and example wouldbe where a hole has been cut in the panel for new pipework,ductwork or electrical services. Such modifications are oftennot finished correctly and are perceived to provide an easyentry point for fire. The question is how big is the risk?

The fact is that Kingspan approved IPN is very difficult to ignite.The images below cover the effect of a high intensity propanetorch on exposed IPN after the metal facings have been removed.The propane torch generates a temperature of over 1000°C.The images show the effect after 30 minutes exposure and area good demonstration of how the IPN forms a strongcarbonaceous char that protects the core foam from ignition.When the burner is removed after 30 minutes the core selfextinguishes. Good practice dictates that any panel damage isrepaired or site modifications are installed correctly – however,the propane torch test does demonstrate that insurer approvedIPN does not ignite and the exposed core does not present afire hazard.

After 30 minutes at over 1000

Section cut through the thickness of the panel after30 minutes exposure showing that the char occurs onlyin the area of direct flame impingement and there isno fire propagation.

Case StudyWharfedale Hospital, 5th July 2003

This is the first recorded fire in a building clad in LPCBapproved isophenic panels. This fire occurred in anextension to the hospital under construction. An arsonistignited a solvent based adhesive poured over a largepile of combustible building materials that was storedin the ground floor of the facility. The ground floor wasessentially open with the external cladding starting at thefirst floor level.

Kingspan commissioned Tenos to perform anindependent investigation into the fire. This involved avisit to site and discussions with the Fire & Rescue Team.A detailed report is available.

Image 1Side of the building exposed to direct flame impingement andsmoke/heat damage from the ground floor. It is clear that theIPN core has not ignited and has played no role in the fire.

Image 2The side of the building that experienced a bigger fireattack. Flames appear to have risen to the eaves – a height ofapproximately 10 metres. The external steel Sheet has bowedand delaminated in the areas of flame impingement-however,there is no indication the fire has spread through the cladding.

Sections were cut out of the short panels in the middleof this photograph in order to inspect the steel columnbehind the panels. The next photograph shows this moreclearly.

Image 3Close-up of the inspection holes cut in the panel after the fire.The insulation core can be seen clearly and looks to be virtuallyunaffected by the direct flame impingement on the outer steelfacing. The steel column was not affected.

Image 4A panel that has been exposed to direct flameimpingement on the outer sheet. The metal has beenpulled away by contractors to inspect the isopheniccore. It is clear that the insulation core has been almostunaffected by the fire. Onyl light charring can be seen.

ConclusionThe Tenos report concludes – “In spite of significantheat generated by the fire (sufficient to damage theintumescent coating and distort the steel beams); theorientation of the cladding panels directly above the fire;and the fact that the fire stopping was not in place; thecores of the panels as evidenced by photograph 2, 3 and4 did not ignite; did not promote fire spread within thecore or to the eaves and did not significantly contributeto the products of combustion.”

These photographs provide a record of the damage andinclude some explanatory comments.

“Protecting business and propertywith FireSafe insurer approved systems”

KINGSPAN’S RANGE OFFIRESAFE ISOPHENIC (IPN) PANELS

• Firesafe is Kingspan’s range of insurer approved panels

• These panels with a sophisticated Isophenic core will not promote fire spread,are self extinguishing and give off minimal smoke in a real fire situation

• The most important way of distinguishing between different panel systems isthrough fire testing. Building regulation tests are important in this respect butit must always be remembered that the key objective of building regulationguidance is to ensure that personnel can leave the building safely in the eventof a fire. (EI resistance tests)

• Property conservation is not a key consideration to regulators – In stark contrastto insurers and investors!

• Kingspan believes that the only way to test any cladding system is to performa realistic scale test on the composite product – incorporating realistic jointdetails and fixings.

• The new Euroclass Reaction to Fire Tests do not fully assess panel performanceand should not be taken in isolation.

• Insurers recognise the limitations of the small scale reaction to fire tests usedtodemonstrate compliance and have developed their own tests such asFM & LPCB

• Insurance certificates available are ‘FM Global’ & ‘LPCB’

• FM Global is an American insurance agency which carries out stringent largescale fire tests. Kingspan has FM unlimited approval.

• Even clients not insured by FM Global will request FM standard productsbecause of their stringent product testing.

• LPC was purchased by the Building Research Establishment (BRE) from ABI(Association of British Insurers) & Lloyds in 2000. LPCB provide research,testing and Fire test Approvals. LPS 1181 is a wall and ceiling test for insulatedpanels. LPCB are promoting the LPS 1181 test across Central Europe.

• External claddings that are LPCB approved to LPS1181 can be classed as‘non-combustible building’, Association of British Insurers (ABI) May 2003

• Kingspan’s unique firesafe blend is a patented formula which can not be copiedby our competitors.

• If you would like to see a fire test on our Firesafe Isophenic panels pleasecontact any Kingspan office

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