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I n s u l a t e d P a n e l s
SystemsLook for the logo
Building to the Power of
Property Insurer Fire Certification Requirements
Contents
IntroductionKingspan 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 assesspanel 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 3 Insurance Certification 4 Fire Test 6Facts and confirmed research 9Myths and Misinformation 10Case study 12Firesafe at a glance 14
Insurance Certifi cationFactory Mutual Global (FM)
Approval Requirements
FM Global (FM), formally known as Factory Mutual, has a severe test standard for assessing reaction to fire. This test standard is FMRC 4880 (1994) Approval requirements for Class 1 fire classification with no height restriction.
Achievement of Class 1 with no height restriction is dependent on performance in a number 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)
The FM Global FMRC 4880 maximum 50 ft (15.24 metres) height wall test is very severe. Two walls 15.24 m high with a small ceiling are lined with panels and a large fire source (345kg dry timber) is positioned in the corner. To achieve approval there has to be no flame spread or fire propagation to the extremities of the panel construction. Kingspan FM approved panels are well within these limits with no flame spread away from the fire source.
LPCBThe loss Prevention Certification Board (LPCB) provides stringent large scale fire testing, certification, approval procedures and guidance contained in the LPCB Design Guide for the Fire Protection of Buildings. These require that the approved systems/equipment are fit-for-purpose when needed.
The building fabric is an important part of any insurance assessment. Choice of an FM approved panel system or an appropriate grade of LPCB approved panel will lead to -
No Additional PremiumNo Additional Excess
APPROVED
Approved to LPS 1181Certificate No’s. 186a, 260a & 279c
Approved to LPS 1208Certificate No. 186b & 279b
certs
Naas Fire Station
Naas
Project NameProduct
ColourUsage
Naas Fire StationKS1000 RW Roof TrapezoidalMerlinEmergency Fire Services
Insurer Certifi cation Requirements
FM 50ft Room Corner Test
The images on these 2 pages show a sequence from ignition to 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 to the edge of the enclosure and no ignition of the ceiling. The Kingspan panels are well within these limits proving that the panels do not promote the spread of fire.
As a result of this test, and other large scale tests Kingspan wall, roof and ceiling panels are approved by FM Global for use without any restriction in height.
Insurer Certifi cation Requirements
Fire is contained in the room corner - no evidence of fire propagation
LPS 1181 Fire Tests
Large Scale Fire Testing
-LPS 1181 Test
The key parameters of the test include:
Fully developed fire -1 mega watt fire load.
Max temp > 1,000 °C at internal liner.
LPS 1181 test designed to assess flame spread, ignition and promote flash over conditions.
Kingspan 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.
Panels removed after LPC test show no spread of flame
Facts and Confi rmed Research
Although the rigid isophenic used in the panels is unsurpassed in its thermal insulating properties, it is basically combustable, like all organic substances.
But the historical fire performance and insurance loss statistics relating to the use of Kingspan isophenic (IPN) panels in the external envelope has been excellent. There is no evidence whatsoever to suggest that Kingspan panel systems are not fit-for- purpose and there is no link with higher insurer losses. This is proven by detailed insurer loss statistics and case studies on fires in buildings clad with such panels.
The following findings can be summarized from the research carried out on many real fires where Kingspan insulated roof and wall systems were in use:
The panels do not contribute to a fire. They are only damaged in the immediate area of the fire and self-extinguish after the fire load has gone
By forming a protective char layer, the fire is starved of oxygen between the metallic skins of the panel. The panels are thus self-extinguishing and do not contribute to a fire.
Thermoset rigid isophenic (IPN) does not melt or drip when exposed to fire. Thus, the danger of igniting secondary fires does not arise.
The gases given off when isophenic foam burns are less toxic than those given off by conventional building materials (e.g. wood)
When used as roof cladding, the sandwich panels resist the spread of fire and reduce radiant heat
The additional fire load caused by isophenic panels varies between 3 and 6 kWh/m2 and therefore has very little effect on a fire. This very low value results from the low density of the insulating foam core which is approximately 41 kg/m3
The results from the standardised tests used to determine combustibility are confirmed completely by the behaviour of the panels in practice
Conclusion
The behaviour of KINGSPAN insulated roof and wall panels in a fire is similar to that of other fire-resistant building materials.
With respect to current fire regulations and the need to build passive fire protection into a structure, insulated isophenic panel systems are amongst the safest proven building methods.
Combustibility of installed panel systems
In recent years, huge confusion has been caused by panel manufacturers and their suppliers making claim and counter claim about the non-combustibility or otherwise of their own and their competitors panel systems.
ABI Definitions of Construction 2003(ABI - Association of British Insurers)The following table outlines the ABI´s Definitions of Construction
Defi nition Description
FIRE RESISTING All elements of construction (including fl oors) to be non-combustible and achieve at least 90 minutes fi re resistance
NON COMBUSTIBLE All elements of construction to be non-combustible OR approved to LPS 1181 INCLUDES KINGSPAN FIRESAFE IPN
PARTLY COMBUSTIBLE Any building having from 10% up to 35% construction elements of combustible construction.
COMBUSTIBLE Any building having between 35% and 70% of combustible materials in the elements of construction.
HIGHLY COMBUSTIBLE Any building having over 70% of combustible materials in their element of construction
Myths & Misinformation
A propane torch reduces polystyrene to flammable gas and liquid in seconds
Combustibility of Real-Life Panel Installations
The reality is that all panel systems have varying levels of combustibility because all contain combustible materials. The only reliable way of assessing panel system combustibility is to base a judgement on testing the entire system. Tests and standards such as LPS 1181, LPS 1208 and FM 4880 are ideal in this respect. The varying levels and grades of performance defined by these tests allow the specific panel system performance to 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 highly flammable and easily ignites. This performance is in stark contrast to isophenic a thermosetting material, which forms a strong carbonaceous char protecting the core from further attack.
The real issue is not directly related to the combustibility of the panel system core - all have combustible elements.The real issue is related to how a specific system will perform in a real fire scenario and whether it acts as non-combustible building element by not contributing to fire.
Myths & Misinformation
Ignitability of Kingspan Fire Rated IPN
One concern raised by insurers is the potential for exposed insulation in ‘real’ situations. The reality is that any insulation panel system is likely to be damaged or modified after installation and this may lead to exposure of the core – and example would be where a hole has been cut in the panel for new pipework, ductwork or electrical services. Such modifications are often not finished correctly and are perceived to provide an easy entry 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 propane torch 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 are a good demonstration of how the IPN forms a strong carbonaceous char that protects the core foam from ignition. When the burner is removed after 30 minutes the core self extinguishes.
Good practice dictates that any panel damage is repaired or site modifications are installed correctly – however, the propane torch test does demonstrate that insurer approved IPN does not ignite and the exposed core does not present a fire hazard.
After 30 minutes at over 1000
Section cut through the thickness of the panel after 30 minutes exposure showing that the char occurs only in the area of direct flame impingement and there is no fire propagation.
Case StudyWharfedale Hospital, 5th July 2003This is the first recorded fire in a building clad in LPCB approved isophenic panels. This fire occurred in an extension to the hospital under construction. An arsonist ignited a solvent based adhesive poured over a large pile of combustible building materials that was stored in the ground floor of the facility. The ground floor was essentially open with the external cladding starting at the first floor level.
Kingspan commissioned Tenos to perform an independent investigation into the fire. This involved a visit to site and discussions with the Fire & Rescue Team. A detailed report is available.
ConclusionThe Tenos report concludes – “In spite of significant heat generated by the fire (sufficient to damage the intumescent coating and distort the steel beams); the orientation of the cladding panels directly above the fire; and the fact that the fire stopping was not in place; the cores of the panels as evidenced by photograph 2, 3 and 4 did not ignite; did not promote fire spread within the core or to the eaves and did not significantly contribute to the products of combustion.”
These photographs provide a record of the damage and include some explanatory comments.
Image 1
Image 4
Image 2 Image 3
Image 1Side of the building exposed to direct fl ame
impingement and smoke/heat damage from the ground fl oor. It is clear that the IPN core has not ignited and has played no role in the fi re.
Image 2The side of the building that experienced a bigger fi re
attack. Flames appear to have risen to the eaves – a height of approximately 10 metres. The external steel sheet has bowed and delaminated in the areas of fl ame impingement – however, there is no indication the fi re has spread through the cladding.
Sections were cut out of the short panels in the middle of this photograph in order to inspect the steel column behind the panels. The next photograph shows this more clearly.
Image 3Close-up of the inspection holes cut in the panel
after the fi re. The insulation core can be seen clearly and looks to be virtually unaff ected by the direct fl ame impingement on the outer steel facing. The steel column was not aff ected.
Image 4A panel that has been exposed to direct fl ame
impingement on the outer sheet. The metal has been pulled away by contractors to inspect the isophenic core. It is clear that the insulation core has been almost unaff ected by the fi re. Only light charring can be seen.
“Protecting business and property
with insurer approved systems”
KINGSPAN’S RANGE OF FIRESAFE ISOPHENIC (IPN) PANELS
ü Firesafe is Kingspan’s range of insurer approved panelsü These panels with a sophisticated Isophenic core will not promote fire spread,
are self extinguishing and give off minimal smoke in a real fire situationü The most important way of distinguishing between different panel systems
is through fire testing. Building regulation tests are important in this respect but it must always be remembered that the key objective of building regulation guidance is to ensure that personnel can leave the building safely in the event of a fire. (EI resistance tests)
ü Property conservation is not a key consideration to regulators – In stark contrast to insurers and investors!
ü 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.
ü The new Euroclass Reaction to Fire Tests do not fully assess panel performance and should not be taken in isolation.
ü Insurers recognise the limitations of the small scale reaction to fire tests used to demonstrate compliance and have developed their own tests such as FM & LPCB
ü Insurance certificates available are ‘FM Global’ & ‘LPCB’ü FM Global is an American insurance agency which carries out stringent large
scale fire tests. Kingspan has FM unlimited approval which means the panels can be used on buildings of unlimited height
ü Even clients not insured by FM Global will request FM standard products because of their stringent product testing.
ü 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 insulated panels. LPCB are promoting the LPS 1181 test across Central Europe.
ü External claddings that are LPCB approved to LPS1181 can be classed as ‘non-combustible building’, Association of British Insurers (ABI) May 2003
ü Kingspan’s unique firesafe blend is a patented formula which can not be copied by our competitors.
ü If you would like to see a fire test on our Firesafe Isophenic panels please contact any Kingspan office
Look for the logo
Identification PlaquesFire officer and insurance surveyor identification plaques are used for rapid identification of building fabric Kingspan maintain a project register of all buildings constructed with roof and wall systems identified by a special registration number.
Kingspan labels are avaiable for attaching to the building to assist property insurers and the brigades.Labels are available on request.
KINGSPAN PANELS PROFILESWall & Facade Systems - horizontal / vertical
EXTERNAL PROFILATIONFor panels with isophenic or mineral fibre insulation
B (box)1
10
6
40 4040 10
6
0,75
17,5 17,5
8,75
M (micro)
1
50 50
E (euro)
For panels with isophenic insulation only
3
50
R 52
W (wave)
259 16 9
0,8
1,5
12,5 24,5 24,5
L (tramline)
9 16 9 299299
1,5
S (segment)
8 8
1
N (mini micro)
INTERNAL PROFILATIONFor panels with isophenic or mineral fibre insulation
B (box)
1
10
6
40 4040 10
6
1
33,33 33,33 33,33
MB (minibox) F (flat)
Roof Systems - pitched / flatPanels with isophenic insulation
Panels with mineral fibre insulation Rooflight panels
FF RM RW / GRP MK1 RW / GRP MK3
XD
Please consult the colour range with Kingspan Technical Design Bureau. * KS 1000 RW can be used as wall panel
RW SM SX
RT
Kingspan Limited
Czech Republic: Telephone: +420 495 866 111, Fax: +420 495 866 100, Email: [email protected] Slovakia: Telephone: +421 244 635 326, Fax: +421 244 635 325, Email: [email protected] Germany: Telephone: +49 281 952 50-0, Fax: +49 281 952 5050, Email: [email protected] Austria: Telephone: +43 120 501 75 100, Fax: +43 120 501 75 900, Email: [email protected] Poland: Telephone: +48 48 378 31 00, Fax: +48 48 378 13 30, Email: [email protected] Lithuania: Telephone: +370 37 451 883, Fax: +370 37 451 885, Email: [email protected] Hungary: Telephone: +36 29 573 400, Fax: +36 29 573 401, Email: [email protected] Romania: Telephone: +40 21 231 50 89, Fax: +40 21 231 50 89, Email: [email protected] Croatia: Telephone: +385 1 464 80 51, Fax: +385 1 464 80 52, Email: [email protected] Serbia: Telephone: +381 24 671 525, Fax: +381 25 535 057, Email: [email protected]
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