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A major step to arrest fire casualtiesFire-retardant (FR) materials have become an important ingredient in modern construction. With more and more skyscrapers towering towards the skies in bustling cities, fire protection has taken centre stage across the world. Using genuine FR material is critical to safety in the Fire Rated Construction System.

A real 2-hour escape windowA typical ACP-cladded façade in India has a frame structure comprising a non-load-bearing brick wall, followed by plaster, steel frame and an ACP envelope fixed on the frame. As an important criterion for resistance to fire, the ACP envelope should contain fire and retain its structural integrity up to 2 hours. But that’s not the only feature that contributes to fire protection. An authentic rating for resistance to fire also takes into account that smoke kills faster than fire, among other vital factors. This is where Aludecor’s FR ACP, FireWall stands above the rest.

FR ACP

Air gap

Weather silicon Backer rodAluminium frame

Brick wall

Plaster

Authentic FR material minimises fire risks

The core secretFireWall is a non-halogenated FR material that produces water vapour when it heats up. It does not produce toxic gases like the halogenated materials.

Magnesium hydroxide (MDH) is the non-halogenated material that is mixed with PE to form the core of Aludecor’s FR products. MDH has a better fire-resistance performance than aluminium trihydrate (ATH), the other non-halogenated material, owing to higher decomposition temperature. Furthermore MDH is more environment-friendly than other similar materials.

MDH delays the PE transformation from solid to plastic (the point of ignition) up to 360°C, by releasing water molecules and bringing down the temperature continuously.

Core details Polyethylene Magnesium hydroxide (MDH)

Aluminium trihydrate (ATH)

Chemical reaction CH2 + O2 = CO2 + H2O Mg(OH)2 = MgO + H2O 2Al(OH)3 = Al2O3 + 3H2O

Decomposition temperature 90

oC to 110

oC 310

oC to 360

oC 190

oC to 240

oC

Status Heat generation Heat absorption Heat absorption

Basic chemical reaction of the FireWall core

Heated MDH releases water molecules that lower the temparature

Mg

OHOH

The trusted choice

will not contribute to rapid spreading of flames towards the upper floors of the building, for 2 hours, as an exterior cladding of a typical Indian construction.

will not melt into flaming droplets and instead turn into innocuous dust particles.

will not come off the façade when the building is doused with water through fire hose.

will not produce toxic gases that cause death. 80% of death in a fire accident is caused by smoke which is a dreadful combination of CO and CO2. The haemoglobin in our blood loves carbon monoxide much more than oxygen.

will not blur vision and thus make it easy for people to get out via the escape routes.

will not release excessive heat onto other materials that can cause fire.

Aludecor’s FireWall having more than 71% mineral content and made with AA5005/AA3105 alloy, is a tried and tested non-halogenated FR ACP which . . .

The state-of-the-art FR grade ACP production unitAt Aludecor the end-to-end production facility is foolproof and competes with global standards. The two production units, spread over 25,000 sq m at Haridwar, are equipped with up-to-date technology and testing facilities. The stringent quality control system keeps a sharp eye on each and every unit produced.

Product certifications and reportsAludecor FireWall is process certified for Reaction to Fire by ewcl5 as per EN 13501-1, Class B-s1, d0 and BS 476 Part 6 and 7.

Aludecor FireWall also passed the ASTM E119-12 test for 2-hour resistance to fire. The test also checks if the ACP disintegrates from the structure when water is sprayed through fire hoses to bring the fire under control.

EN 13501-1 test validates that it will not contribute to the spreading of fire; that smoke production will be negligible and flaming droplets will turn to harmless ash particles. On clearing this test Aludecor FireWall has received the B-s1, d0 fire classification.Tested at Exova Warringtonfire, UK

The all-important baby stepUp-to-date ACP Lines

FireWall ACPs are manufactured in Aludecor’s fully equipped ACP Lines, but not before the mineral core undergoes rigorous scrutiny.

Aludecor is equipped with Baby Line, a miniature version of an ACP Lamination Line, for trial production of the Aludecor mineral core. The mineral core produced in this Baby Line is subjected to rigorous tests, and only on clearing them, is the particular batch sent for final production.

Smoke Density TestLimiting Oxygen Index

The Drum Peel Test is done to check the bonding strength.

Drum Peel Test

Checks the minimum oxygen requirement to ignite the material.

The Limiting Oxygen Index is a measure of the percentage of oxygen that has to be present to support combustion of the plastic materials. The benchmark is 21%. Below this the material will catch fire easily, but above it the tendency will be reduced. The higher the LOI value, the higher the non-flammability.

Checks if light passes through the smoke produced or not, so that it does not blur human vision.

Smoke Density Index (SDI) helps to measure the concentration of smoke emitted by burning materials.

Higher SDI rating means that the material emits a greater quantity of smoke, when burning, than low density rated materials. We know that smoke kills faster than fire and causes more fatality than heat. Smoke produces life-threatening toxic products and reduces visibility. It also hinders escape from a fire zone.

It’s important to keep in mind that ASTM D 2843 is an important method to measure the SDI rating of plastics.

FireWall retains all the original properties of Aludecor ACPs . . .

• Best workability and flexibility with no crack risks • Unmatched flatness • Highest gloss retention • Superb weather-resistance and longevity

Winning product attributes

Quality check at the in-house FR LabBefore going for the final production, each batch of the mineral core produced in the Baby Line is thoroughly tested.

Non-combustibility Test Checks at what temperature the material would be set aflame.

Materials that catch fire easily are more ignitable, flammable or combustible. For example, paper is more ignitable or flammable than wood. Various testing procedures can be treated as effective tools to quantify the capability of any material to resist fire. There are international protocols in place to determine the flammability or combustibility of different kinds of substances.

The EN13501-1 is an effective way to test combustibility of various materials.

Ignitability Test Checks the magnitude of ignition in compliance with EN1182.

Rating Degree of flammability Example

A1 100% non-combustible Rockwool

A2 98% non-combustible Gypsum plaster

B Difficult to ignite Some high-end silicones

C Normal combustibility Wood

D Easily ignited or flammable Polystyrene, paper etc

Various categories that determine the degree of combustibility as well as flammability

Technical specificationsSL# Description Standard Unit FireWall

1

Physical properties panel

Thickness mm 4

2 Weight Kg/Sqm 7.6

3 Thermal expansion ASTM D696 x10-6/oC 24

4 Deflection temperature ISO 75-2 oC 116

5 Thermal conductivity W/m-k 0.45

6Physical properties alloy

Thickness 0.5mm

7 Grade AA5005/AA3105

8

Mechanical properties of composite panel

Tensile strength ASTM E8 Mpa(Na/mm2) 45

9 0.2% proof stress ASTM E8 Mpa(N/mm2) 40

10 Elongation ASTM E8 % 5

11 Drum peel torque ASTM D1781 N mm/mm 190

12 Mechanical properties of aluminium skin

Tensile strength ASTM E8 Mpa(N/mm2) Min. 152

13 0.2% proof stress ASTM E8 Mpa(N/mm2) Min. 136

14 Elongation ASTM E8 % 5

15

Coating details

Coating type AAMA 2605 PVDF

16 Coating thickness AAMA 2605

25 to 28 microns 2-coat-system; 30-35 microns 3-coat-system

17 Formability ASTM D1737 T 2T

18 Weather-O-Meter test ASTM D2244

i) Gloss retention 70% after 4000 hrs

ii) Colour retention Max 5 Units after 4000 hrs

iii) Chalk resistance Max 8 Units after 4000 hrs

19

Fire properties

Limiting Oxygen Index ASTM-D 2863 45

20 Degree of Smoke Density ASTM-D 2843 5

21 Ignitability test ISO : 11925-2:2010

Sample does not catch flame up to 10 minutes, by continuous flaming

22 Flash Point/Ignition Temp ISO : 1182:2010 oC ≥500

23 Europe EN 13501-1 (B-s1, d0) Pass

24 USA ASTM E119 2 hrs

25 British standards BS 476 Part 6 & 7 Pass

26 Germany DIN 4102-1 Class B1 Pass

Width Length Thickness Squareness Bow

Coil Panel

3mm ±2.0mm ±4.0mm ±0.02mm ±0.2mm Maximum 5.0mm

Maximum 0.8% of width and/or length

4mm ±2.0mm ±4.0mm ±0.02mm ±0.2mm Maximum 5.0mm

Maximum 0.5% of width and/or length

6mm ±2.0mm ±4.0mm ±0.02mm ±0.3mm Maximum 5.0mm

Maximum 0.5% of width and/or length

Product Tolerance

Product dimension and toleranceTo facilitate planning of fabrication and installation excerpts from panel dimensions have been given below.

Thickness 3mm 4mm 6mm

Weight 6.0 kg/m2 7.6 kg/m2 10.9 kg/m2

Top and bottom coil thicknesses

0.25mm 0.5mm 0.5mm

Standard width 1220mm

Length 6100mm

Product Dimension

Cleaning and handling1. Cleaning the light surface soiling

Rinse with water all the way. Keep the water volume low. Moderate pressure is recommended. Rub the surface with soft sponge or cloth.

a. If rinsing and sponging fail use a mild detergent after diluting it.

b. While using the mild detergent, clean the surface first horizontally then with vertical motion.

c. Don’t let the detergent drip and splash and rinse immediately to prevent marks. Use clean water to rinse.

2. Cleaning heavily soiled surface

Soiling caused by grease and sealing material can be removed by certain types of alcohol like IPA (Isopropyl Alcohol), ethanol or N-hexane diluted 50% with water. Do not use strong solvents that contain cleaners as they might spoil the surface. Start with a spot test over a small area and wash the residue with mild soap and water.

3. Note of caution

a. Do not proceed to clean without doing a spot test in an unseen area.

b. Avoid abrasive cleaners.

c. Do not rub too much or too hard.

d. Ensure there are minimum drips and splashes and quickly wash and wipe away rundowns.

e. Cleaning should be done on the shaded side of the building and extremely high and low temperatures must be avoided.

f. Avoid paint removers, acid cleaners and strong alkali solvents like MEK (Methyl Ethyl Ketone), MIBK (Methyl Isobutyl Ketone), Treclene (Tri-chloroethylene) or thinner.

g. The cleaning sponges and cloth pieces should be soft and free of grit.

h. Never mix cleaners.

4. Practical tips on cleaning

Cleaners and detergents are normally local products. A cleaner or a detergent widely available in one country may not be available in another country. To confirm the harmlessness of your cleaner, contact local distributors or our office. We will conduct a test with your cleaner sample.

How to handleAvoid physical impact since it may damage the edges. Make sure there are no hard particles like sand or cutting chips between the panels because those may cause damage. Follow the instructions below during fabrication and installation . . .

1. How to unpack and repack

a. Choose a clean workplace for unpacking and repacking.

b. Remove dust from the panels and the packing paper to avoid any possibility of dents.

c. Use a table, not the floor, to handle Aludecor FireWall.

d. Engage at least two people to handle the panels which should face upward to avoid rubbing of the surface.

2. How to transport

During transportation place Aludecor FireWall in a horizontal position and do not put anything heavy on top of the panels. Remember to mark with instructions like ‘Handle with Care’, ‘Keep Dry’, ‘No Hooks’ and ‘This Side Up’ on the packaging.

3. How to fabricate

a. Before fabrication clean the work-table, the temporary stand and the panels.

b. Remove all cutting chips since those can cause damage to the panels during the process of fabrication.

4. How to store

a. Always store Aludecor FireWall indoors using a flat or vertical rack system as shown below.

b. If you are using a flat rack system put panels of the same size on a rigid palette. You can stack up to 4 wooden crates on top of each other.

c. If you have a vertical rack system panels, they should lean against an inclined backing material within a 10-degree incline. The leaning panels should not be thicker than 10 mm. Veneers are the ideal backing cover and it’s advisable to use a rubber mat at the bottom. Make sure not to scratch the panels when pulling out or putting back.

5. PVC Tape

Adhesive tape made of PVC (polyvinyl chloride) should not be used on the protective film at any point during storage, fabrication and installation. The plasticiser in the PVC tape can seep in through the film and cause damage to the lumiflon coating on the panels. Avoid using PVC tapes including duct tape, packing tape and insulation tape.

3-2 Proper storing method

Flat Rack Vertical Rack

Kalpataru Mumbai

NIELIT Delhi

Shangri-La Hotel Bengaluru

Smart City Kochi

The glory story