Michael Rahm and Per Blomqvist
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SP Report 2015:15Fire testing on cork - furan/glass fibre
sandwich panel for marine application
Michael Rahm and Per Blomqvist
Abstract
The purpose of the FIRE-RESIST project, a European Commission supported project, aimed at improving the fire performance of high performance polymer matrix composite materials for the transport sectors. One concept for load carrying structures was
developed for marine applications. This concept was a sandwich consisting of three cork cores and four furan/glass fibre laminates. The ambition with the multiple layer design was to create a structural redundancy allowing parts of the sandwich cross-section to decompose when exposed to fire without a total loss of load carrying capacity.
A limited engineering analysis with regards to SOLAS II/2-17 was performed resulting in a set of requirements on the fire behaviour of the sandwich. A series of tests, both small and large scale, were performed to investigate if these requirements were met.
The results from these tests show that the requirements were met when an intumescent coating was applied. All test procedures and results are documented in this report. Key words: FRP, Fire, composites, IMO, SOLAS, furan, glass fibre, cork
SP Sveriges Tekniska Forskningsinstitut SP Technical Research Institute of Sweden SP Report 2015:15
ISBN 978-91-88001-45-0 ISSN 0284-5172
Contents
Abstract
3
Contents
4
Acknowledgments
5
Sammanfattning
6
1
Introduction
7
2
Method
8
2.1 Full scale fire resistance testing 8
2.1.1 Temperature measurements and observations 9
2.2 Reduced scale fire resistance testing 10
2.2.1 Temperature measurements 11
2.3 Reaction to fire testing 12
2.3.1 Part 5 Test for surface flammability 13
2.3.2 Part 2 Fire test procedures for smoke generation 14
3
Materials
14
3.1 Reduced scale fire resistance testing 14
3.2 Full scale testing 15
3.3 Reaction to fire testing 15
3.4 Surface weight, density and moisture content 15
3.4.1 Surface weight 15
3.4.2 Moisture content 15
4
Results
16
4.1 Full scale fire resistance testing 16
4.1.1 Temperature measurements 16
4.1.2 Observations intumescent coating 17
4.1.3 Damage documentation 17
4.2 Reduced scale fire resistance testing 18
4.2.1 Results specimen 1 18
4.2.2 Results Specimen 2 19
4.2.3 Results Specimen 3 21
4.2.4 Damage documentation 22
4.3 Reaction to fire testing 24
4.3.1 Test for surface flammability according to part 5 24 4.3.2 Smoke and toxicity test according to part 2 26
5
Discussion and conclusions
27
6
References
28
Appendix 1 – Observations intumescent coating
Appendix 2 – Test report large scale fire resistance test
Appendix 3 – Rest report for surface flammability testing
Appendix 4 – Test report for smoke and toxicity tests
Acknowledgments
The research leading to these results presented here has received funding from the European Community's Seventh Framework Programme (FP7/2007-2013) under grant agreement no. 246037. The authors are grateful to the Fire-Resist consortium for allowing the publication of this information in the form of a SP Report.
The Fire-Resist consortium include the following partners: - Newcastle University (coordinator)
- Airbus Group
- Innovations - Composites Technologies, - Bombardier Transportation (UK) Ltd,
- Flensburger Schiffbau-Gesellschaft mbH & Co. KG - DNV-GL
- Cytec UK
- Amorim Cork Composites SA - TransFurans Chemicals BVBA
- Anthony, Patrick and Murta Exportação Lda, - APC Composite AB (SE)
- BALance Technology Consulting GmbH, PROPLAST - Fundación Gaiker
- Institut National des Sciences Appliquées de Lyon - SP Sveriges Tekniska Forskningsinstitut AB - Swerea SICOMP AB
- VTT Technical Research Centre of Finland, Steinbeis Advanced Risk Technologies GmbH
Sammanfattning
Som en del av FIRE-RESIST projektet, ett EU-finansierat projekt som syftade till att förbättra brandegenskaperna för högpresterande polymermatris-kompositmaterial för utvalda transportsektorer (flyg, tåg, fartyg), har en fallstudie med en maritim applikation definierats och utvärderats mot relevanta krav. Den utvalda komponenten för fallstudien var ett bärande komposit-skott för överbyggnaden på ett RoPax fartyg.
När brännbara material introduceras i bärande konstruktioner på en SOLAS fartyg innebär det en avvikelse från de föreskrivna brandskyddskraven. Det korrekta sättet att hantera en sådan avvikelse är att utföra en teknisk analys enligt SOLAS II/2-17 - "alternativa utformningar".
En begränsad analys av brandsäkerheten utfördes inom projektet och ett resultat av denna analys var prestandakriterier med avseende på både brandmotstånd och branddynamik som komponenten för sjöfartsfallstudien måste uppfylla.
En serie brandförsök genomfördes för att visa på överensstämmelse med kraven på prestanda. Dessa tester dokumenteras i denna rapport.
1
Introduction
As a part of “WP6 - Application and evaluation of fire-resisting technologies” SP Fire Research has conducted fire testing of a novel composite bulkhead design. The ambition for the marine application was to demonstrate a sandwich design suitable to use as a load bearing bulkhead on a SOLAS classed RoPAX ship. Figure 1 shows a section of a superstructure on a RoPAX ship, the intention was to show the potential of replacing the A60 bulkhead between the corridor and weather deck with the sandwich design
developed in the Fire-Resist project.
Figure 1 – Superstructure section identified as interesting showcase for marine application.
The design consists of four glass fibre reinforced furan laminates and three balsa cores. To further improve fire resistance as well as reaction-to-fire characteristics the surface facing the corridor was covered with an intumescent coating.
Figure 2 – Section showing the principal of the bulkhead design consisting of four furan/glass fibre laminates, three cork cores and an intumescent coating.
division is a deviation to the prescriptive requirements stating that an A-class division must be of “Steel or equivalent material” i.e. non-combustible. However, according to SOLAS II-2/17 [1] it is possible to deviate from the prescriptive fire safety requirements as long as the fire safety objectives and functional requirements are met. Within WP6 a limited engineering analysis with regards to SOLAS II-2/17 was performed [3] and fire testing of the novel design had to be performed to support this analysis. In the
engineering analysis report the following requirements on the novel design were identified:
• Fire resistance of at least FRD60 according to Part 11 in the FTP-code [2]; o Load bearing capacity; 7 kN/m vertical load for 60 minutes o Insulation, after 60 minutes;
Average temperature rise on unexposed surface < 140 °C Individual temperature rise on unexposed surface < 180 °C o Integrity, for 60 minutes;
No flaming on the unexposed face No ignition of the cotton-wool pad
It shall not be possible to enter the gap gauges into any opening in the specimen
• Reaction to fire properties of internal surfaces must reach low flame spread characteristics;
o FTP-code Part 2 – smoke and toxicity test o FTP-code Part 5 – test for surface flammability
Reaction to fire properties of external surfaces or active fire protection systems must prevent external flame spread.
The test programme also included mini-furnace tests (SP Fire 119) to get indicative results on fire resistance of the sandwich bulkhead prior to the large-scale furnace test (the FTP-code Part 11 test). The applicability of the results of the mini-furnace tests for predicting large scale fire resistance behaviour was additionally evaluated.
2
Method
2.1
Full scale fire resistance testing
A large-scale fire resistance test according to Part 11 in the FTP code [2] was performed to verify that the demonstrator reached the FRD60 criteria.
The test specimen was mounted in a frame of reinforced concrete (SP´s loading frame) with the original opening dimensions (width × height) 3060 × 3000 mm. In order to accommodate the test specimen the opening in the concrete frame was reduced by a plinth constructed by aerated concrete. The size of the reduced opening was (width × height) 2960 × 2850 mm.
The test specimen was mounted in the reduced opening in the concrete frame. The test specimen was simply supported along the top and bottom edges and was unrestrained (i.e.
free to move) along the vertical edges. The spaces between the vertical edges of the test specimen and the concrete frame were sealed with mineral wool insulation. On top of the test specimen loading equipment was applied and the bulkhead was subjected to vertical loading during the test.
According to IMO Res. MSC.307(88), 2010 FTP code, Part 11, the load should be a uniformly distributed load, as far as practicable, of 7 kN/m of the width of the test specimen.
The load was applied with two hydraulic pistons and a load distribution beam of steel. The total load from the hydraulic pistons together with the weight of the load distribution beam before and during the heating was 21 kN, i.e. 7,0 kN/m of the bulkhead width. The concrete frame with the test specimen was placed on SP´s vertical furnace after the mounting, see Figure 3. The fire exposed side was the side with the intumescent paint.
Figure 3 - Novel bulkhead design mounted on the vertical furnace before the test was started.
2.1.1
Temperature measurements and observations
The temperature rise on the unexposed surface of the bulkhead was measured with 5 thermocouples (C1 – C5) in accordance to the test standard.
In addition to what is required in the test standard internal temperatures at 20 different positions in the sandwich mas measured (C6 – C25). All thermocouple positions are found in Figure 4.
The internal face, i.e. the surface within the furnace, of the test specimen was visually observed during the test through a small window in the back of the furnace to document the behavior of the intumescent coating. The swelling and the adhesion of the coating to the laminate of the test specimen was important parameters to observe.
Figure 4 - Thermocouple positions in the full scale test.
2.2
Reduced scale fire resistance testing
The test method used was the gas fired mini-furnace described in test method SP Fire 119 [4]. The SP fire 119 test is in general used for product development and research before larger and more expensive standardized tests are performed.
Three small-scale tests were performed. The first test was performed to get an indication of the performance of a preliminary design. The specimen in the second test had the same cross section dimensions as the full scale specimen, with intumescent coating to see how well temperature measurements correlate between full scale and reduced scale testing. The third test was without intumescent coating to get an indication of what impact the coating has on the demonstrator’s fire resistance performance.
Figure 5 – Mini-furnace before a specimen is mounted.
2.2.1
Temperature measurements
The general test set-up is shown in Figure 6.
Figure 6 – Mini-furnace with specimen mounted.
The test specimen had the dimensions 600 mm × 500 mm (L × W). Totally 14 thermocouples were installed at different depths and at different positions on the specimen.
834) surface thermocouples; type K, thermocouples with insulating pads and copper disks. These were glued to the surface of the test specimen. An extra tape was attached for guaranteeing a safer attachment.
Nine thermocouples were installed at different depths in in the test specimens. The temperature on the upper side of the three lower laminates (except the upper non-exposed laminate which was equipped with five copper disc thermocouples) was measured in three positions.
The test specimen in all three tests was equipped with thermocouples according to Figure 7.
Figure 7 – Thermocouple positions in the reduced scale tests.
2.3
Reaction to fire testing
In the engineering analysis performed according to SOLAS II/2-17 it was concluded that all internal surfaces must, at least, achieve low flame spread characteristics to be accepted as equivalent with regards to surface flammability and smoke potential and toxicity. This means that the internal surfaces of the demonstrator must pass the criteria for part 2 and part 5 in the FTP code.
For external surfaces it was concluded that the reaction to fire properties or active fire protection systems must prevent external flame spread. In previous research [5] this has been tested in large scale in SP´s façade test rig [6] and the results has shown that a drencher system providing a discharge density of 3 l/m2*min is sufficient to reach this criterion. The same study also showed that composite materials with good reaction to fire properties in combination with intumescent coating can reach this criterion.
For the maritime demonstrator in Fire-Resist no large scale façade test was performed.
2.3.1
Part 5 Test for surface flammability
FTP Part 5 described in the FTP code, also known as “spread of flame”, where the sample is subjected to an irradiation and the criteria for passing the test is related to the length of the flame spread as a function of radiation level. This test is used, e.g., for testing of floating floors and surface lining material.
The demonstrator sandwich design, see Figure 2, was tested for surface flammability both with the coated surface and with the non-coated surface exposed. The coated surface represents an internal surface and the non-coated surface represents an external surface.
2.3.2
Part 2 Fire test procedures for smoke generation
FTP Part 2 described in the FTP code is a test for production of smoke and toxic
combustion gases. The sample is placed in a test box where it is irradiated with a heating cone. Light obscuration is measured by a photometric system and the concentrations of selected toxic gases are measured using FTIR (Fourier Transform InfraRed) technique. The demonstrator sandwich design was tested for smoke production and toxicity with the painted surface exposed. The painted surface represents an internal surface.
Figure 9 – Smoke box and FTIR test equipment used for testing according to part 2 in the FTP code.
3
Materials
3.1
Reduced scale fire resistance testing
Three different specimens were tested in the mini-furnace. All three of them had the outer dimensions (width × height) 600 ×500 mm. The specimens consisted of a structural sandwich with three 14 mm thick cores of cork wood material and four laminates of glass fiber reinforced furan.
Apart from the above the three specimens had the following features:
Specimen 1, preliminary design tested to get an indication of fire resistance performance: The outer laminates had a nominal thickness of 3 mm and the inner laminates had a thickness of 1.5 mm. The specimen was painted on one side with 1 mm paint designated Nullfire S707-60. The nominal thickness of the specimen was 52 mm.
Specimen 2, final sandwich design representing an internal bulkhead surface: The outer laminates had a nominal thickness of 3 mm and the inner laminates had a thickness of 4 mm. The specimen was painted on one side with 1 mm paint designated Nullfire S707-60. The nominal thickness of the specimen was 57 mm.
Specimen 3, final sandwich design representing an external bulkhead surface: The outer laminates had a nominal thickness of 3 mm and the inner laminates had a thickness of 4 mm. The specimen was not painted on any side. The nominal thickness of the specimen was 56 mm.
3.2
Full scale testing
The test specimen consisted of a load-bearing bulkhead with the outer dimensions (width × height) 3000 × 3000 mm. The bulkhead consisted of a structural sandwich with three cores of cork wood material and four laminates of glass fiber reinforced furan with a nominal thickness of 4 mm in each layer and 3 mm in the outer layers. The specimen was painted on one side with 1 mm paint designated Nullfire S707-60. The nominal thickness of the specimen was 57 mm, 14 mm in each layer of cork.
3.3
Reaction to fire testing
Sample specimens for the reaction-to-fire testing were produced for the final sandwich design in number and dimensions according to the requirements in IMO 2010 FTP Code. The “spread of flame test”, FTP Part 5, requires sample species of 155 mm × 795 mm (L × W) and the “smoke and toxicity test”, FTP Part 2, requires sample species of 75 mm × 75 mm (L × W).
3.4
Surface weight, density and moisture content
All test specimens were manufactured and delivered to SP by APC Composites AB. All of the specimens, except for specimen 1 in the reduced scale fire resistance test series, were manufactured in the same batch and arrived at SP on October 23, 2014. From the time of delivery the specimens for fire resistance testing was stored in SP´s furnace hall with an average temperature of 18 °C and an average relative humidity of 62%. The specimen for reaction-to-fire testing were stored in a conditioning room with controlled ambient conditions maintained at 23 °C ± 2 °C and 50% RH ± 2 % RH.Surface weight and moisture content was measured on a small specimen prepared for reaction-to-fire testing.
3.4.1
Surface weight
A test specimen with the dimensions 134 mm × 134.5 mm [W × L] had a mass of 632.6 g which corresponds to a surface weight of 35.1 kg/m2.
The large panel for full scale fire resistance testing with the dimensions 3000 mm x 3000 mm [W × H] had a mass of 291 kg which corresponds to a surface weight of 32.3 kg/m2.
3.4.2
Moisture content
A small waste part from the test preparation for the reaction to fire testing was initially cut down to half of the initial thickness resulting in a 28 mm thick specimen without any intumescent coating. This specimen was cut to 5-7 mm thick strips which was weighed, dried in an oven at 105 °C for 72 hours and then weighed again. The strips weighed 34.15 g before drying and 31.76 g after which corresponds to a moisture content of 7.0 %. The moisture content measurement was started November 7th 2014 and finished
4
Results
4.1
Full scale fire resistance testing
The full scale fire resistance test was performed November 4th, 2014. A detailed test report according to requirements in the FTP-code is found in Appendix 1.
The bulkhead failed after 77 minutes due to loss of load bearing capacity. After 60 minutes the average temperature rise on unexposed surface was 5 °C (< 140 °C requirement) and the maximum individual temperature rise on unexposed surface was 6 °C (< 180 °C requirement). Further, the integrity was maintained until the load bearing capacity was lost after 77 minutes.
Figure 10 shows the bulkhead shortly after failure.
Figure 10 – Novel bulkhead design seconds after loss of load bearing capacity
4.1.1
Temperature measurements
As shown in Figure 4 the temperature in five positions was measured on the unexposed side of each laminate and in the centre core. The average temperatures for each laminate and the centre core are presented in Figure 11. The measurements for each individual thermocouple are found in Appendix 2.
Figure 11 – Large scale test. Average temperatures measured on the unexposed side of each laminate and in the centre core until the time of structural collapse.
Collapse occurs when the second laminate reached approximately 180 °C.
4.1.2
Observations intumescent coating
During the large scale fire resistance test photos were taken through a small observation window on the backside of the furnace. It was fully possible to follow how the coating expanded, cracked up and eventually fell of the bulkhead. Photos and observations are presented in Appendix 1.
4.1.3
Damage documentation
After the test a part of the sandwich was cut out to allow documentation of the damages from the test. This piece was cut out from the upper centre part of the bulkhead. When the test was aborted the remaining fire was extinguished with water, thus charred cork and possibly some undamaged cork have been washed away.
It can be seen that the second laminate (from the fire exposed side) has detached from the centre core and that much of the centre core seems relatively undamaged. The third core and the two last laminates (from the fire exposed side) look totally undamaged.
0 50 100 150 200 250 300 350 400 450 500 0 10 20 30 40 50 60 70 80 90 Te m pe ra tu re [° C] Time [min]
Avg. temp. 1st lam Avg. temp. 2nd lam Avg. temp. 3rd lam Avg. temp. 4th lam Avg. temp. Centre core
Figure 12 – Observed damages to the bulkhead after the test.
4.2
Reduced scale fire resistance testing
4.2.1
Results specimen 1
The test was performed September 31st 2014 to get an indication if the preliminary design would be successful in the loaded large scale fire resistance test in November.
The test was aborted after 81 minutes. At that time the integrity was still intact and the peak temperature on the unexposed side had only risen with 43 °C. After 60 minutes the maximum temperature rise was 22 °C. Thus the specimen performed well with regards to insulation and integrity.
However, the thesis was that the bulkhead would lose its load carrying capacity when the second laminate, from the fire exposed face, reaches 150-200 °C. Average temperatures of the unexposed side of each laminates are presented in Figure 13 and it can be seen that the second laminate reaches critical temperatures after about 45 minutes. Based on these results the bulkhead design was altered before the large scale test.
Figure 13 – Specimen 1. Average temperatures measured on the unexposed side of each laminate.
4.2.2
Results Specimen 2
The test was performed November 18th 2014 (i.e. after the large scale test) to investigate how well the reduced scale testing correlates with the loaded large scale fire resistance test.
The test was aborted after 80 minutes. At that time the integrity was still intact and the peak temperature on the unexposed side had only risen with 26 °C. After 60 minutes the maximum temperature rise was 12 °C. Thus the specimen performed well with regards to insulation and integrity.
Average temperatures of the unexposed side of each laminates are presented in Figure 14. A comparison of the laminate temperatures from the test with specimen 2 and the large scale vertical furnace test is presented in Figure 15.
0 100 200 300 400 500 600 700 800 0 10 20 30 40 50 60 70 80 90 Te m pe ra tu re [° C] Time [min] Avg. 1st laminate Avd 2nd laminate Avg 3rd laminate Avg 4th laminate
Figure 14 - Specimen 2. Average temperatures measured on the unexposed side of each laminate.
Figure 15 – Comparison of average laminate temperatures from the mini furnace test with specimen 2 (coated) and the large scale vertical furnace test.
When comparing the average laminate temperatures from the test with specimen 2 and the large scale vertical furnace test it can be seen that the temperatures correlates quite well, at least until the temperatures reaches about 200 °C.
0 50 100 150 200 250 300 350 400 450 0 10 20 30 40 50 60 70 80 90 Te m pe ra tu re [° C] Time [min] Avg 1st laminate Avg 2nd laminate Avg 3rd laminate Avg 4th laminate 0 50 100 150 200 250 300 350 400 450 500 0 10 20 30 40 50 60 70 80 90 Te m pe ra tu re [° C] Time [min] 1st lam coated 2nd lam coated 3rd lam coated 4th lam coated 1st lam large scale 2nd lam large scale 3rd lam large scale 4th lam large scale
Considering the thesis that the bulkhead would lose its load carrying capacity when the second laminate, from the fire exposed face reaches 150-200 °C, it seems like the small scale test gives a good indication on when this might occur.
4.2.3
Results Specimen 3
The test was performed November 19th 2014 to get an indication if an uncoated bulkhead would be successful in a loaded large scale fire resistance test.
The test was aborted after 80 minutes. At that time the integrity was still intact and the peak temperature on the unexposed side had only risen with 37 °C. After 60 minutes the maximum temperature rise was 16 °C. Thus also this specimen performed well with regards to insulation and integrity.
Average temperatures of the unexposed side of each laminates are presented in Figure 16. A comparison of the laminate temperatures from the test with specimen 2, specimen 3 and the large scale vertical furnace test is presented in Figure 17.
Figure 16 - Specimen 3. Average temperatures measured on the unexposed side of each laminate.
0 100 200 300 400 500 600 700 800 900 1000 0 10 20 30 40 50 60 70 80 90 Te m pe ra tu re [° C] Time [min] Avg 1st laminate Avg 2nd laminate Avg 3rd laminate Avg 4th laminate
Figure 17 - Comparison of average laminate temperatures from the mini furnace test with specimen 2 (coated), specimen 3 (uncoated) and the large scale vertical furnace test.
When comparing the laminate temperatures measured on specimen 3 and specimen 2 it is obvious that the intumescent coating has a significant effect on the temperatures in the sandwich. In the large scale test the bulkhead lost its load carrying capacity when the second laminate reached about 180 °C. The results from the test with specimen 3 indicate that a bulkhead without intumescent coating would collapse after about 50 – 60 minutes in a loaded large scale test in the vertical furnace.
4.2.4
Damage documentation
After the tests the sandwich panels where cut in half to allow documentation of the damages from the test. Figure 18 and Figure 19 shows the damages on specimen 2 and specimen 3 after testing.
On specimen 2 it can be seen that the second laminate (from the fire exposed side) has been affected but the centre core seems relatively undamaged.
On specimen 3 it can be seen that the second laminate and the centre core is severely affected.
The third core and the two last laminates (from the fire exposed side) look undamaged for both specimens. 0 50 100 150 200 250 300 350 400 450 0 10 20 30 40 50 60 70 80 90 Te m pe ra tu re [° C] Time [min] 1st lam coated 2nd lam coated 3rd lam coated 4th lam coated 1st lam uncoated 2nd lam uncoated 3rd lam uncoated 4th lam uncoated 1st lam large scale 2nd lam large scale 3rd lam large scale 4th lam large scale
Figure 18 - Observed damages to specimen 2 after the test.
4.3
Reaction to fire testing
4.3.1
Test for surface flammability according to part 5
A full test series (3 tests) was performed on the sandwich design with intumescent
coating and a reduced test series (2 tests) was performed on the sandwich without coating. The surface flammability criteria according to Part 5 in the FTP code are:
• CFE, critical flux at extinguishment: ≥ 20.0 kW/m2 • Qsb, average heat for sustained burning: ≥ 1.5 MJ/m2 • Qt, total heat release: ≤ 0.7 (0.2) MJ
• Qp, peak heat release rate: ≤ 4.0 (1.0) kW
If values within brackets for Qt and Qp are reached the product is considered to comply also with Part 2 without further testing.
Complete test reports from these test series are found in Appendix 3. The key results from these tests are presented in Table 1 and
Table 2.
Table 1 – Results from tests according to Part 5 on sandwich with intumescent coating.
Test no 1 2 3 Average Surface flammability
criteria Heat for ignition,
MJ/m2 -* -* -* -*
Average heat for sustained burning, Qsb, MJ/m2 -** -** -** -** ≥ 1.5 Critical flux at extinguishment, CFE, kW/m2 48.4 48.4 48.4 48.4 ≥ 20.0
Total heat release, Qt,
MJ < 0.1 < 0.1 < 0.1 < 0.1 ≤ 0.7 Peak heat release
rate, Qp, kW
< 0.1 < 0.1 < 0.1 < 0.1 ≤ 4.0 * Not calculated (extent of burn < 150 mm).
Table 2 - Results from tests according to Part 5 on sandwich without intumescent coating.
Test no 1 2 3 Average* Surface flammability
criteria Heat for ignition,
MJ/m2 4.40 3.50 - 4.0
Average heat for sustained burning, Qsb, MJ/m2 4.40 3.70 - 4.1 ≥ 1.5 Critical flux at extinguishment, CFE, kW/m2 12.4 16.5 - 14.5 ≥ 20.0
Total heat release,
Qt, MJ 0.70 0.70 - 0.7 ≤ 0.7
Peak heat release
rate, Qp, kW 6.3 3.9 - 5.1 ≤ 4.0
* Average based on two measured value.
It can be seen that the sandwich with coating reaches low flame spread characteristics (i.e. is considered to comply also with Part 2) without further testing. The sandwich without coating does not quite reach the surface flammability criteria.
4.3.2
Smoke and toxicity test according to part 2
A full test series was performed on the sandwich design with intumescent coating. The design without coating is not considered relevant for internal surfaces and was not tested according to part 2 in the FTP code.
The samples were tested under each of the following conditions: • Irradiance of 25 kW/m2 in the presence of pilot flame. • Irradiance of 25 kW/m2 in the absence of pilot flame. • Irradiance of 50 kW/m2 in the absence of pilot flame. At all of these three conditions the following criteria must be met:
• Dm, average maximum specific optical density, ≤ 200 • Gas concentration limits:
o CO 1 450 ppm o HCl 600 ppm o HF 600 ppm o NOX 350 ppm o HBr 600 ppm o HCN 140 ppm o SO2 120 ppm
A complete test report from this test series is found in Appendix 4. The key results from these tests are presented in Table 3.
Table 3 – Average results from tests according to Part 2 on sandwich with intumescent coating.
Limit 25 kW/m2 with pilot flame 25 kW/m 2 without pilot flame 50 kW/m 2 with pilot flame Dm 200 81 97 134 CO conc. 1 450 ppm 260 132 692 HF conc. 600 ppm <5 <5 <5 HCl conc. 600 ppm 16 15 15 HBr conc. 600 ppm <10 <10 <10 HCN conc. 140 ppm 39 27 123 NOX conc. 350 ppm 43 <20 26 SO2 conc. 120 ppm <10 <10 <10
5
Discussion and conclusions
The maritime demonstrator reached the set criterion for fire resistance. The criterion was to perform as a “Loadbearing fire-resisting bulkhead 60”.
• The bulkhead maintained integrity for more than 60 minutes; the bulkhead failed first after 77 minutes due to loss of load bearing capacity.
• With regards to insulation the design performs very well in comparison to the requirements; e.g. after 60 minutes the maximum individual temperature rise on unexposed surface was only 6 °C.
The mini-furnace tests showed a good correlation with the large-scale test. If failure conditions are well understood the mini furnace test can be a useful development tool and give a good indication on how a sandwich design will perform in large scale fire
resistance testing.
Based on mini furnace testing it was estimated that the maritime demonstrator without the intumescent coating would last about 50 – 60 minutes in a loaded test in the vertical furnace.
The intumescent coating had a significant effect on the fire resistance. A rough estimation is that the intumescent coating provided an additional 20 minutes of fire resistance. However, it was observed that the expanded foam layer from the coating was brittle and fell off the bulkhead after a period of time in the tests. Conditions in real fire scenarios might be such that turbulence, deformations and vibrations causes the foam to fall off at an earlier stage than in the standardized tests.
The maritime demonstrator reached the set criterion for reaction to fire. The criterion was to reach “Low flame spread characteristics” i.e. to comply with part 5 and part 2 in the FTP code. The demonstrator without intumescent coating did not reach this criterion. According to Part 11 in the FTP code materials used in “Loadbearing fire-resisting divisions” shall be non-combustible or fire-restricting as verified in accordance with part 1 or 10 in the FTP code. The demonstrator evaluated in this report has not been tested according to these methods. It is obvious that the non-combustibility criterion is
impossible to reach with this design and it is unknown if the material would pass the fire-restricting material criteria which requires a successful test according to ISO 9705 – the room corner test
However, fire-restricting material was not defined as a criterion to demonstrate
equivalence in the engineering analysis according to SOLAS II/2-17 that was performed in the Fire resist project.
6
References
1. IMO, “SOLAS Consolidated Edition 2009”, International Maritime Organization, London, 2009.
2. FTP code IMO, “2010 FTP Code: International Code for Application of Fire Test Procedures, 2010”, 2012 edition, International Maritime Organization, London, 2012.
3. Daniel Povel, Hazard Identification – A-60 composite outside wall, DNV GL-report MAGDE717, Hamburg, 2014.
4. SP Fire 119, Fire test of building constructions in a small-scale furnace (in Swedish), issue 5, 2012.
5. Franz Evegren, Rahm, M., Arvidson, M., Hertzberg, T., Fire testing of external combustible ship surfaces, Borås, Sweden, 2014.
6. SP Fire Technology, “SP Fire 105, External wall assemblies and facade claddings: Reaction to fire”, Issue No: 5, SP Technical Research Institute of Sweden, Borås, 1994.
Appendix 1 – Observations intumescent coating
During the large scale fire resistance test photos were taken through a small observation window on the backside of the furnace. Photos and observations are presented below. Test time[min] Comment Photo
1 min Short after test start. The coating has started to be affected by the heat.
5 min The coating has turned black and started to expand. Small cracks on the coating start to appear.
Bigger cracks appear on the coating.
13 min The coating seems to be fully expanded. Cracks in coating grow further.
22 min Flakes of expanded coating starts to detach from the laminate but have not yet fallen of.
29 min First large piece of coating falls of. This is positioned left of the
bulkhead centre, seen from inside the furnace.
33 min Flakes of coating continue to detach.
41 min A second piece of expanded coating falls off. This is positioned near the centre of the bulkhead.
upper right corner of the bulkhead.
48 min The fire exposed laminate seem to, at least partially, have detached from the sandwich.
58 min More coating falls off near the upper right corner.
65 min The right side of the bulkhead has almost no coating left. The exposed laminate is obviously not attached to the rest of the sandwich panel.
Appendix 2 – Test report large scale fire resistance
test
1002 ISO/IEC 17025 Contact person Date Reference Page
Torben Ronstad 2014-12-15 BRf6112-2 rev 1 1 (8) Fire Research +46 10 516 58 35 Torben.Ronstad@sp.se European Commission Enterprise and Industry DG BE-1049 BRYSSEL Belgien
Fire test of a loadbearing bulkhead
(20 appendices)
SP Technical Research Institute of Sweden
Postal address Office location Phone / Fax / E-mail Laboratories are accredited by the Swedish Board for Accreditation and Conformity Assessment (SWEDAC) under the terms of Swedish legislation. This report may not be reproduced other than in full, except with the prior written approval of the issuing laboratory.
SP Box 857 SE-501 15 BORÅS Sweden Västeråsen Brinellgatan 4 SE-504 62 BORÅS +46 10 516 50 00 +46 33 13 55 02 info@sp.se Test method
IMO Res. MSC.307(88), 2010 FTP code, Part 11. Deviation from the test method
• Drawing including a detailed schedule of components and a method of assembly have not been presented. The drawings should include dimensions and details of the thickness of insulation and so forth. (Deviation from Part 3 §2.1.3)
Product
Loadbearing bulkhead
Product designation
Load bearing triple sandwich cork wood bulkhead
Sponsor
European Commission Enterprise and Industry DG BE-1049 BRYSSEL Belgien
BRf6112-2
This report replaces the previous edition dated 2014-11-13. Rev 1: The test method is changed in test.
SP Technical Research Institute of Sweden
1
Purpose of the test
The purpose of the test was to determine the fire resistance of the test specimen described in paragraph 2.
2
Test specimen
The test specimen consisted of a load-bearing bulkhead with the outer dimensions
(width x height) 3000 x 3000 mm. The bulkhead consisted of a structural triple sandwich core of cork wood material which was painted on one side with paint designated Nullfire S707-60.
2.1
Number of specimens
According to IMO Res. MSC.307(88), 2010 FTP code, Part 11 a bulkhead tested for “general application” should be tested with fire against each side separately.
On request from the sponsor the bulkhead was tested with fire from one side only. The exposed side was the side with the layer of paint.
2.2
Delivery, assembling and mounting of the test specimen
The test specimen of the structural triple sandwich core was selected by the sponsor of the test. The test specimen was manufactured and delivered to SP by the sponsor. The test specimen arrived at SP in October 23, 2014.
The test specimen was mounted in a supporting construction by SP on November 3, 2014.
2.3
Description of the test specimen
Structural coreThe structural core consisted of a triple sandwich panel. The dimensions of the triple sandwich panel (width x height) was 3000 x 3000 mm and the nominal thickness was 57 mm, 14 mm in each layer of cork.
The triple sandwich construction consisted of a core material of cork wood with laminate on each side of the core material and with two laminate layers in between the triple core with a nominal thickness of 4 mm in each layer and 3 mm in the outer layers.
Paint
The structural core was painted with paint designated Nullfire S707-60 with a nominal thickness of 1 mm on one side.
SP Technical Research Institute of Sweden
2.4
Supporting construction and mounting of the test specimen
The test specimen was mounted in a frame of reinforced concrete ( SPs loading frame) with the original opening dimensions (width x height) 3060 x 3000 mm. In order to accommodate the test specimen the opening in the concrete frame was reduced by a plinth constructed by aerated concrete. The size of the reduced opening was (width x height) 2960 x 2850 mm. The test specimen was mounted in the reduced opening in the concrete frame. The test specimen was simply supported along the top and bottom edges and was unrestrained (i.e free to move) along the vertical edges. The spaces between the vertical edges of the test specimen and the concrete frame were sealed with rock wool insulation. On top of the test specimen a loading equipment was applied, see also chapter 3.2.
The test specimen was mounted in the supporting construction in such a way that the exposed area of the test specimen (width x height) was 2960 x 2850 mm, see also appendices 1- 2. The mounting of the test specimen in the supporting construction was performed by SP. The concrete frame with the test specimen was placed on SP´s vertical furnace after the mounting. The exposed side was the side with the layer of paint.
2.5
Conditioning
The test specimen was stored in SP’s furnace hall before the test. The temperature in the furnace hall was in average 18° C and the relative humidity was in average 62 % during this time.
2.6
Verification of the test specimen
2.6.1 Conformity of the test specimen with drawings and specifications
The assembling of the test specimen in SP´s furnace hall was overseen by SP. The conformity of the test specimen with the drawings and specifications provided by the sponsor was
surveyed by SP in conjunction with the assembling. 2.6.2 Verification of included materials
Test specimen Density
(kg/m3)
Moisture ratio 1)
(%)
Cork 271 7
1) Moisture ratio calculated from weight loss after being heated at 105 °C.
The verification was performed on November 5, 2015 on samples from the same batch of material as the materials used in the test specimen.
SP Technical Research Institute of Sweden 2.6.3 Non-combustibility of included materials
According to 3 Additional requirements in IMO Res. MSC.307(88), 2010 FTP code, Part 11 valid test reports regarding the non-combustibility or fire-restricting material of the included materials should be enclosed in the test report. The sponsor has neither supplied SP with such reports nor given SP the assignment to perform such tests.
3
Test procedure and test results
The test was performed on November 4, 2014. The test specimen was loaded prior to and during the fire test (the heating period). The fire test lasted 77,5 minutes.
The test procedure is described in appendix 3.
3.1
Witness of test
The test was witnessed by Mr Anton Lindgren, Mr Peter Nordström from APC Composites AB and Mr Pavel Golyshev from DNVGL.
3.2
Loading
The bulkhead was subjected to loading during the test. According to IMO Res. MSC.307(88), 2010 FTP code, Part 11, the load should be a uniformly distributed load, as far as practicable, of 7 kN/m of the width of the test specimen. The test load was applied approximately 16 minutes before the heating and directly after the heating the test specimen was unloaded. See also appendix 3.
The loading arrangement is shown in appendices 1-2.
The load was applied with two hydraulic pistons and a load distribution beam of steel. The total load from the hydraulic pistons together with the weight of the load distribution beam before and during the heating was 21 kN, i.e 7,0 kN/m of the bulkhead width.
The load applied to the bulkhead is shown in a graph in appendix 4.
3.3
Furnace control
The furnace was controlled in accordance IMO Res. MSC.307(88), 2010 FTP code, Part 11. 3.3.1 Temperatures
The furnace temperature was measured with 6 thermocouples (PT1-PT6). The hot junctions of the thermocouples were positioned approximately 100 mm from the fire exposed surface of the test specimen at the commencement of the test.
SP Technical Research Institute of Sweden
The furnace was controlled so that the average temperature of the 6 thermocouples followed the standard time-temperature curve.
The average temperature (of PT1-PT6) in the furnace in relation to the standard time-temperature curve is shown in a graph in appendix 5.
The temperature at each thermocouple (PT1-PT6) in relation to the standard time-temperature curve and permitted deviation, is shown in a graph in appendix 6.
The percent deviation of the area under the average furnace time-temperature curve from the area under the standard time-temperature curve and permitted deviation, is shown in a graph in appendix 7.
The temperature in the laboratory at the commencement of the fire test was 18 °C. 3.3.2 Pressure
The pressure in the furnace in relation to the ambient pressure in SP´s furnace hall was
measured at level 500 mm above the lower edge of the bulkhead (the notional floor level of the test specimen).
The furnace pressure was controlled so that a zero-pressure was kept at level 500 mm above the lower edge of the bulkhead (the notional floor level of the test specimen).
The furnace pressure is shown in a graph in appendix 8. 3.3.3 Ambient temperature
The ambient air temperature was measured with one thermocouple. The ambient air temperature at the commencement of the test was 18 °C.
3.4
Measurements on the test specimen
3.4.1 Temperatures3.4.1.1 Temperatures on the unexposed surface
The temperature rise on the unexposed surface of the bulkhead was measured with 5 thermocouples (C1 – C5). The thermocouples were positioned as shown in appendix 9. The temperature rise and the average temperature rise on the unexposed surface of the bulkhead (average of thermocouples C1 – C5) are shown in a graph in appendix 10 and in tabular form in appendix 11.
SP Technical Research Institute of Sweden 3.4.1.2 Optional temperatures – internal temperatures
The internal temperature was measured with 20 thermocouples (C6 – C25). The thermocouples were positioned as shown in appendix 12.
The temperature inside the bulkhead is shown in a graph in appendices 13 – 16.
The average temperature of thermocouples C6 – C25 at beginning of the test was 19 °C. 3.4.2 Deflection
The axial contraction and the horizontal deflection of the test specimen during the test were measured with electronic deflection transducers (linear potentiometers).
The points for measuring axial contraction (Dy1 – Dy2) were located on the spreader beam, vertically above the upper right and left corners of the test specimen. The points for measuring horizontal deflections (Dz1 – Dz3) were located at the centre of the test specimen and 50 mm in from the free vertical edges, at mid-height of the test specimen. See appendix 17. The measurements began prior to the application of the load.
The axial contraction is shown in a graph in appendix 18. The maximum axial contraction during the fire test was 9 mm (deflection downwards) before the failure of the load-bearing ability.
The horizontal deflection is shown in a graph in appendix 19. The maximum horizontal deflection was 23 mm.
3.5
Observations
Photographs taken in connection with the test are shown in appendix 20. 3.5.1 Observations during the test
Time min:s
Observations (the observations refer to the unexposed side if nothing else is stated)
-26:00 Application of the test load commences. -16:00 The test load is applied to the test specimen. 00:00 The heating period commences.
01:40 Smoke emits at upper corners on both sides. 03:00 Smoke emits at the top of the specimen. 05:30 The state is unchanged.
10:30 The state is unchanged.
15:35 Smoke emits on the right side at mid height. 20:15 More heavy smoke emits on left side at mid height.
26:15 Smoke emits from the bottom of the specimen in line with TC4. 30:30 The state is unchanged.
SP Technical Research Institute of Sweden
39:20 A cracking sound is heard from the specimen. 45:30 Moisture can be seen along both sides. 53:00 The state is unchanged.
60:00 The state is unchanged.
63:15 The smoke is increasing in intensity.
71:00 Lines in the bulkhead surface appear more visible. 75:00 The smoke is increasing even more in intensity.
77:00 A sudden collapse of the test specimen and the test specimen was compressed and bulges in the middle of the upper half out from the furnace.
77:30 The test is terminated due to safety reasons.
Tests with cotton wool pads were not performed during the test since any leakage of hot gases were observed.
Tests with gap gauges were not performed during the test since no through gaps were observed.
4
Summary
A loadbearing bulkhead, described in chapter 2, has been fire tested according to IMO Res. MSC.307(88), 2010 FTP code, Part 11. The test load was applied approximately 30 minutes prior to the heating period. The heating period lasted 77,5 minutes when it was discontinued due to incipient failure of the load-bearing ability.
The following results were obtained: Insulation
• The maximum average temperature rise (average of C1-C5) on the unexposed face of the bulkhead did not exceed 140 °C during the test.
• The maximum temperature rise on the unexposed face of the bulkhead did not exceed 180 °C during the test.
Integrity
• The integrity was maintained during the test. Loadbearing ability, 7kN/m
• The bulkhead fulfilled the performance criteria for loadbearing ability of fire-resisting bulkheads during the test.
The test results relate only to the behaviour of the test specimen during the conditions of the test. At other conditions, for instance another fire curve, the behaviour of the construction may differ from the presented test results.
SP Technical Research Institute of Sweden
5
Classification
A bulkhead constructed as described in this report may be regarded as a Loadbearing fire-resisting bulkhead 60
According to IMO Res. MSC.307(88), 2010 FTP code, Part 11, when exposed to fire against the insulated side and if all the materials of the construction are non-combustible or fire-restricting.
Approval of the construction may be obtained only on application to appropriate Administration.
SP Technical Research Institute of Sweden
Fire Research - Fire ResistancePerformed by Examined by
__Signature_1 __Signature_2
Torben Ronstad Patrik Johansson
Appendices 1-20 (one page per appendix).
Support and perimeter details
Exposed wldth 3000 740 1420 740 Scale: Sign:1:30
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Spreo.der beo.M Free edgeJ Free edge StructurQl coreA gQp of 30 MM between t he structurQl core Qnd the test f rQMe so thQt both
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Concrete fro.Me
The gQps Qre pQcked wlt h rock wool to provlde Q seQl wit hout restricting freedoM of MoveMent.
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Insulo. tion for protection of the concrete beo.M o.ncl of the spreo.der beo.M
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1:30
Fire test of a load-bearing bulkhead.
Test method: 2010 FTP CODE
Test specimen:
Loadbearing bulkhead with a structural core of cork wood material in three layers with laminate
in between and on each side.
Structural core painted with paint designated Nullfire 5707-60 an the fire exposed side
Structural core overall dimension, (width x heightl, 3000 x 3000 mm.
Exposed area, [width x heightl. 3000 x 2850 mm.
Mounting of the test specimen:
The painted tripplesandwich bulkhead is simply supported at the top and the bottom and is not
supported along the vertical edges.
lnsulation and integrity
The insulation and integrity performance of the bulkhead is evaluated during the test. The
evaluation and performance criterias areas described in the test method.
Contraction and deformation
Measurements of the axial contraction and of the horizontal deflection are made during the
test.
Test laSld <stSltlc lo(ld)•
A load-level af 7,0kN/m of the width of the strutural core is applied uniformly along the top
edge of the structural core.
The load is applied with two hydraulic pistens on top af a spreader beam af steel. The total
load, including the load from the weight of the spreader beam (4,36 kN). is 3x7=21 kN.
The load from each hydraulic pisten is (21-4,36)/2=8,32 kN.
Test load calculation
According specifications provided by the sponsor the loading was calculated according ta the
table belowe.
TEST 6
~hlc:kness c:ore, MM 53, In three lo.yers
::ore quo.llty Cork [rhlc:kness lo.Mlno.te, MM 3,0000 t:rltlc:o.l loo.d Design, kN/M So.f ty fo.c:tor ,..oo.d test 21 kN Sign:
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