10 Years of Success!

Palusol SW Fire Door Assemblies in North America.

Mike van Geyn, A.Sc.T.

Topics

• Introduction

• Short History of SW product development

• Fire Test Methods used in North America, and

how these compare to Europe

• Fire Resistance ratings

• Certification Requirements

• Overview of the BASF system in North America

• BASF Licensing System

IntroductionMike van Geyn A.Sc.T.• Manager of the Fire Testing Laboratory of

Intertek Testing Services, Vancouver, BC Canada from 1990 to 2010

• Downsized from Intertek in January 2010 due to global economic recession

• Since 2010 – Independent consultant assisting manufacturers in working with the testing laboratories, with the goal of optimizing fire test results, and providing technical assistance.

• My company name is Firestance Professional Services Ltd., providing service to BASF on an as-needed basis.

Short History of Palusol SW Product Development

Palusol SW System Benefits• Allows the construction of fire rated doors of ratings up

to 90 minutes without the use of gypsum or calcium silicate based core materials.

• SW cores allow fire door construction using normal wood working methods and tools.

• SW cores were the first to provide great design flexibility, such as “craftsman style” rather than just flush (flat) doors required by mineral cores.

• Architectural design conformance for all doors on a project, so the fire doors could match the non-fire rated doors.

• Fire Doors could now conform to heritage designs.

Development of Palusol SW Fire Doors

• First fire test program was conducted in April 2005

• Series of 10 fire tests

• Very successful outcome– 45, 60 and 90 minute ratings achieved

– Single swing and pair configurations

– Range of hardware options

• Palusol SW fire door system launched in North America

Development of Palusol SW Fire Doors• Second fire test program conducted in March

2007• Provided cost reductions and expanded the

design offerings– Architectural design glazing system developed for 45,

60 and 90 minute ratings– Double Egress pair configuration up to 90 minutes– More hardware options – SW core splicing methods developed to allow larger

door sizes– Fire door frame design tested using SW core

materials, so a complete door and frame system is provided to BASF customers

Development of Palusol SW Fire Doors

• Two additional fire test programs conducted in April 2013 and March 2016

• Provided increased hardware and door and door frame design options

• Refinements to reduce manufacturing and inventory costs for SW core customers

• Introduced products made by other BASF divisions (Interdens)

• Most comprehensive architectural fire door system available in North America

Fire Testing Methods used in North America

Fire Testing Methods

Fire Test StandardsEurope – BS EN 1634-1, EN 16034

United Kingdom, Gulf States – BS 476 Part 22

North America

Canada – CAN/ULC S104

USA – UL 10b and UL 10c

also - ASTM E152 and NFPA 252

Fire ExposureAll of these test methods use natural gas or propane fuel

furnaces, and a similar fire exposure – time vs temperature curve as shown below (1000 °F = 538 °C).

Furnace Temperature MeasurementThe furnace thermocouples used to measure the

furnace internal temperature are different– EN 16034 uses plate thermocouples that measure

radiant heat

– BS 476 Part 22 uses bare bead thermocouples that provide quick response

– North American methods use shielded thermocouples that have slow response (2 minutes lag)

This results in some exposure differences. The NA exposure is more severe in the first 15 minutes due to thermocouple lag (time required to heat the 20 mm dia. steel tubes that shield the thermocouples).

Differences in Test MethodsDoor/frame test assembly orientation Doors open towards fire for North America Doors open away from fire for EuropeTemperature Rise Criteria• Temperature rise limits are established for 30 and 60

minutes in North America (250 °F and 450 °F)• Temperature Rise is a condition of acceptance for the

final fire rating in Europe.Hose Stream test Criteria• Doors must pass a hose stream test immediately after

the fire test. Required in North America onlyFurnace Internal Pressure• Negative for Canada, Positive everywhere else

Hose Stream TestThe hose stream test is applied using a 65 mm fire

hose nozzle with a 28.5 mm open end. The water pressure is 30 PSI while flowing.The nozzle is located 20 feet (6 m) from the test

assembly.The hose stream duration is based on the rating • 0.6 seconds per square foot of assembly area for

ratings up to 1 hour.• 1.5 seconds per square foot for 1 ½ hr ratings.The hose stream is applied first at the center of the

assembly, and then over all areas, changing direction slowly.

Hose Stream Test Video

Hose Stream Test Criteria

• Doors shall remain in place.

• There shall be no openings that will project a stream of water through the assembly, except for the gap under the door, and allowable separation of the meeting edges of pairs of 10 mm.

• Some glass may be dislodged when evaluating glazing, but perimeter shall be intact.

• In practice, no through openings when viewed normal to the surface of the door, as observed after the hose stream test.

Hose Stream Test – Cont’d• The hose stream test is a mechanical integrity test, to prove

residual strength.• The test evolved from a sand-bag impact test that was

applied to the center of the assembly.• The test in no way relates to the fact that fire fighters use

water to extinguish fires.• The test is very severe, and more door assemblies fail to

achieve a rating due to hose stream test performance than fire test performance.

• The water impact force is not uniform and hence the test vibrates and shakes the assembly, and can dislodge hardware or break components loose.

• Provides an end point to the fire test for post test observation, as the fire exposure and test sample deterioration continues after the furnace burners are turned off.

Post Fire Test Photo

Post Hose Stream test Photo

Post Hose Stream Test Photo

Fire Resistance Ratings• North American building codes allow doors and frames

(closures) to be fire rated for 75% of the fire rating of the wall construction in which they are mounted.

• A 1 hour rated wall requires a ¾ hour rated door, a 2 hour rated wall requires a 1 ½ hour rated door.

• Exception is suite entry doors (occupancy with a bedroom such as apartments and hotels) which require a 20 minute rating. The hose stream test is optional for 20 minute rated doors in USA, but required for Canada

• BASF Palusol SW core door constructions are fire rated for 20, 45, 60 and 90 minutes.

Certification Requirements for North America

3rd Party Certification• Fire doors and frames are considered to be an important

ingredient in the “life safety” provisions of the building codes.

• For this reason, the market requires fire doors to be certified (listed and labelled) by an accredited 3rd party certification agency.

• For Canada accreditation is done by a government agency (SCC) , for the USA it is the building code agency (IAS).

• The main accredited agencies for fire doors are Underwriter’s laboratories Inc. (UL), Intertek Testing Services (WHI), and QAI Laboratories (QAI). The Palusol SW cores are certified by Intertek and QAI, and the Palusolactive ingredient bears UL certification.

• A certification with Guardian Fire is also maintained for the gulf states market.

3rd Party Certification Cont’dCertification encompasses the following steps;• The laboratory documents the materials and

construction of the test samples at the manufacturing location(s) prior to testing.

• The laboratory maintains traceability of the test samples.

• The laboratory tests and evaluates the sample.• The laboratory develops a follow-up procedure and

visits the manufacturing plant 4 times per year to ensure that the product manufactured on an on-going basis conforms to the required specifications as determined by the testing.

• Labels bearing the agency mark are applied to the product to show proof of conformance and of certification.

3rd Party Certification Cont’dThird party certification, inspection and labelling

programs apply at the BASF factory for component manufacturing of Palusol sheet and SW core sheet, and also at each door customer location that manufactures doors and frames using the SW components for sale in Canada and the USA.

The laboratory charges fees on a monthly basis to maintain follow-up service inspection programs.

For Europe, CE marking does not require 3rd party inspection services, but they are available.

Overview of the BASF SW Fire Doors in North America

45 Minute Arch Doors

45 Minute Arch Doors

45 minute Full Door Glazing

45 Minute Communicating Doors

45,60 Minute Grooved Face

60 Minute Stile and Rail Construction

90 Minute Single Door, 5/8” Core

45 minute Frame Drawing

BASF Licensing SystemLicensing fees• Palusol SW customers do not pay an up-front licensing

fee to gain access to the Listings and Specifications.• The customer simply needs to purchase a minimum

quantity of SW component materials.• Once purchase is made, the authorisation is granted to

the laboratory for engaging the customer in a certification program, and to release the proprietary specifications.

• All laboratory listings and construction drawings are publicly available for viewing by potential customers, but proprietary manufacturing and machining specifications are released only on by written authorization by BASF.

Looking ForwardContinued development to expand hardware

options, simplify construction, and reduce system costs. Possible topics are;

• Expand glazing sizes for 60 and 90 minute rated doors, using the simpler clip system.

• Simplify the double egress door construction for all ratings.

• Develop a fire rated multi-paned window frame system that can also include sidelites and transoms.

• Larger sizes for pairs of doors

Thank-You

Mike van Geyn, A.Sc.T.