Introducing a code of
practice for expanded
polystyrene panels
Version 1.0
Authors: John Clampett, Jacqueline Bates and Ron Lawson
IPCA Ltd.
Insulated Panel Council
Australasia Ltd
Formerly EPSA Inc. PMG
1
Executive Summary
The majority of cool store and food processing plants in
Australia Incorporate Expanded Polystyrene (EPS) cored
Insulated Sandwich Panels (ISP) as part of the building
structure. Thus it is no surprise that over the past 30 years
some of these processing plants have been involved in
large scale fire incidents. In some of the incidents there
was concern from the fire authorities that the EPS cored
ISP did not perform as well as expected in fire situations.
Thus the Insulated Panel Council Australasia Incorporated
(IPCA Inc.) embarked upon a research program to review
ways of improving the performance of EPS cored ISP in fire
situations. The results of this research have been transferred
into a practical application with the development of the
Industry Code of Practice (CODE) for EPS cored ISP for Class
7 and 8 Buildings.
The key objective of the CODE is to increase fire fighter
confidence when undertaking their operational role. The
focus of the CODE is on aspects of building construction
manufacturers and installers of ISP have control over
in relation to the structural performance of ISP in a
fire situation. The intention of the CODE is to deliver a
better performing Panel System in a fire. The CODE DOES
NOT mitigate any requirements of the relevant building
legislation. The CODE is not to be used in conjunction with a
fire engineered alternative solution under the performance
provisions of the Building Code of Australia. Design
applications using the CODE as part of a building approval
submission need to consult with the Fire Brigade having
jurisdiction.
Whilst the CODE is voluntary in nature, certification that
a project has been installed to CODE requirements is
administered by the IPCA Inc. The CODE requires specific
design specifications be presented in the application such as;
fixings of external walls to base; wall to wall corner details;
and ceiling with hanging fastener details. The CODE also
requires specific Panel installation details such as; perimeter
suspension to all ceilings -ceilings not to be supported by
panel walls; no nylon fixings or suspensions to be used; steel
flashings and rivets only to be used. The CODE requires that
panel be made with fire grade EPS. The CODE also requires;
emergency and safety measures for refrigerated and cooling
chambers; and post construction recommendations be
provided to end users.
Authors: John Clampett, Jacqueline Bates
and Ron Lawson
2
2
CONTENTS
IPCA Ltd.
Insulated Panel Council
Australasia Ltd
Formerly EPSA Inc. PMG
Version 1.0
1.0 Introduction
5
2.0 Background
5
2.1
What are Insulated Sandwich Panels?
5
2.2
What is EPS?
6
2.3
EPS Flame Retardants
6
2.4
Australian ISP Industry Facts
7
2.5
Development of ISP and Construction Methods
7
2.6
Advantages of Using ISP
7
2.7
Where is ISP Used?
8
2.8
Fire Requirements of the BCA
8
2.8.1
Changes to Building Code of Australia
8
2.8.2
BCA Fire Indices Requirements – AS 1530.3 Testing
8
2.8.3
BCA Group Numbers Requirements – ISO 9705
9
3.0 Literature Review and Code Development
9
3.1
Introduction
9
3.2
Fire Incidents
10
3.3
Improvements to Fixing Methods
10
3.4
Delamination
11
3.5
Fire Spread Within Panel
11
3.6
Ceiling Support
12
3.7
Toxicity of ISP in Fire
12
3.8
Risk Reduction Strategies
12
3.9
Panel Indentification
12
4.0 Implementation of the Code
13
4.1
History
13
4.2
Scope
13
4.3
Objectives
13
4.4
CODE Summary
13
4.5
CODE Specifics
13
3
CONTENTS
IPCA Ltd.
Insulated Panel Council
Australasia Ltd
Formerly EPSA Inc. PMG
Version 1.0
4.0 Implementation of the Code (continued)
4.5.1
Design Detailing and Specification
13
4.5.2
Panel Manufacturing/Type
14
4.5.3
Panel Installation
14
4.5.4
Post Construction Recommendations
15
4.6
Current Signatories to the CODE
15
4.7
Barriers to CODE Uptake
15
4.8
Long Term Plan
15
5.0 Summary
16
CODE Disclaimer and Warning
16
Appendix 1
Example of Checklist Requirements
17
Appendix 2
Example of Risk Management Inspection Form
18
Appendix 3
Example of Key Diagram
19
Appendix 4
Example of Labelling
20
6.0 References
21
5.1
4
13
INTRODUCING A CODE OF PRACTICE
FOR EXPANDED POLYSTYRENE PANELS
IPCA Ltd.
Insulated Panel Council
Australasia Ltd
Formerly EPSA Inc. PMG
Version 1.0
1.0 INTRODUCTION
In line with international trends1 and best practice2,3, the Expanded Polystyrene Association Inc. Panel Manufacturers Group (EPSA PMG) has introduced a
voluntary; industry administered Industry Code of Practice (CODE) for Expanded Polystyrene (EPS) cored Insulated Sandwich Panel (ISP)4 for Class 7 and
8 Buildings1. The key objective of the CODE is to increase fire fighter confidence when undertaking their operational role. The purpose of this paper is to
introduce and explain the CODE, including general background information encompassing; an explanation and history of sandwich panels; development of the
relevant fire test methods in the BCA; a review of relevant literature and events which have lead to development of the code; implementation of the CODE;
and future directions.
This paper also reviews the realities of warehouse and storage facility fires. “A poor workman blames his tools” is a well known saying and is quoted in
regards to a wide range of products and services. This phrase could well be applied to building materials which are involved in fires. A good analogy would
be car accidents, none of us would think of blaming the car in question for car accidents, where excessive speed and or alcohol have been involved, and
can see the benefit of improved safety features in case an accident occurs. In corollary there has been a disproportionate concern about the impact of EPS
cored ISP in large factory fires in which they are part of the structure of a building involved in a fire. This is despite acknowledgment by insurance testing
services5 and other experts that insulated panels in themselves do not start fires or contribute significantly to the spread of the fire, that the cause is always
poor risk management. As with car accidents the outcome of potential fire in Insulated Panels can be mitigated by good design and following standard Risk
Management practices. Hence the CODE has been developed.
2.0 Background
2.1 What are Insulated Sandwich Panels?
Insulated Sandwich Panels (ISP) have been used for commercial construction in Australia for the past 50 years. Sandwich Panels are made when three
separate elements are “sandwiched together” to form one structure see Diagram 1. The combined properties of the; high tensile and compressive strength
of the outer steel skins; and the high shear strength of the inner core leads to a building material which has a much longer spanning capacity and is lighter
weight than traditional building materials. This longer spanning capacity, a 100 mm thick ISP can span 4 - 5m6, drastically reduces the amount of supporting
materials required and the installation time, whilst the tight fitting nature of the joint structure combined with the insulating core leads to a building structure
which very effectively and economically keeps heat in or out of a building.
DIAGRAM 1: typical sandwich panel
steel skins
inner core
slip joint
1
Building Code of Australia, 2007 Volume One Part A3, Classification of buildings and structures, Page 40.
Class 7: A building which is(a) Class 7a – a carpark; or
(b) Class 7b – for storage, or display of goods or produce for sale by wholesale.
Class 8: A laboratory, or a building, in which handicraft or process for the production assembling, altering, repairing, packing, finishing, or cleaning of goods or products is carried on for trade, sale or gain.
5
INTRODUCING A CODE OF PRACTICE
FOR EXPANDED POLYSTYRENE PANELS
IPCA Ltd.
Insulated Panel Council
Australasia Ltd
Formerly EPSA Inc. PMG
Version 1.0
2.2 WHAT IS EPS?
EPS is manufactured from styrene monomer, using a polymerisation process which produces translucent spherical beads of polystyrene, about the size of
sugar granules. During this process a low boiling point hydrocarbon, usually pentane gas is added to the material to assist expansion during subsequent
processing. EPS is produced in a three stage process see Diagram 3. In the first stage, polystyrene beads are expanded to between 40 and 50 times their
original volume by heating to about 100˚C with steam in an enclosed vessel called a pre expander. During this process the beads are stirred continuously. In
this process the final density of EPS is determined. This is typically between 14 kg/m3 and 30 kg/m3. After pre expansion, the expanded beads are cooled
and dried in a fluidised bed drier, before being pneumatically conveyed to storage silos for maturing.
During maturing, the second stage of processing, the expanded beads containing up to 90% air are stabilised typically over a period of 24 hours. Following
pre-expansion, the beads have a partial vacuum which must be equalised before final processing by allowing air to diffuse into the beads until equilibrium is
reached. In the third stage of processing, known as the moulding stage, beads are conveyed into a mould, and once in the mould are heated again by the
introduction of steam. Under the influence of steam, the beads soften and start to expand again. However, as they are contained in a mould they cannot expand
freely, and therefore create an internal pressure within the mould. Under this pressure the softened beads fuse together when the correct temperature is reached
within the mould. Following fusion the mould is cooled, usually under the influence of a vacuum to remove moisture. The moulded product is ejected from the
mould at the completion of the cycle. During processing, the pentane gas is expended, so that the finished products contain no residual gas.
DIAGRAM 2: polystyrene reaction
DIAGRAM 3: ManufacturE of EPS
2
2.3 EPS flame retardants
The flame retardant predominately used for expanded polystyrene is hexabromocyclododecane (HBCD). HBCD is added during the polymerisation process and
is retained within the polymer matrix. When EPS containing HBCD is exposed to a fire source the HBCD decomposition products cause flame quenching, so
that EPS will not continue to burn when the fire source is removed. Studies have shown that levels of HBCD in EPS remain constant over time preserving the
insulation flame retardancy for decades7. While overall fire performance cannot be predicted from small-scale laboratory tests due to the complexity of a real
fire situation, testing by the limiting oxygen index test has clearly shown it is difficult to ignite EPS made with a flame retardant8. The National Academy of
Sciences in the USA studied potential health risks of flame retardants9 and concluded that eight flame retardants (including HBCD) posed little or no health risk.
2
6
Schematic courtesy of EPSA PMG.
INTRODUCING A CODE OF PRACTICE
FOR EXPANDED POLYSTYRENE PANELS
IPCA Ltd.
Insulated Panel Council
Australasia Ltd
Formerly EPSA Inc. PMG
Version 1.0
2.4 australian isp industry facts
• 6,000,000m2 of ISP is estimated to be produced and installed annually across Australia.
• Competitive, mature market.
• Approximately $2 billion turnover annually.
• 5,000 people directly employed.
• 100,000,000m2 of ISP estimated to be currently installed across Australia.
2.5 development of isp and construction methods
Up until 1986 EPS cored ISP was predominantly flat steel adhered to EPS and joined together with a small aluminium H section, usually with a masonite
spline. The slip joint (see Diagram 1) was developed by Bondor in 1986 for the Expo 88 buildings, and has since become the standard joint type for adhered
panel, both in Australia and internationally. In 1992, AS 1366.310 was updated to include a new grade of EPS - Fire Retardant or FR- EPS, this is the standard
core in most panel supplied in Australia. EPS with a fire retardant added significantly reduces its propensity to burn when confronted with a naked flame11.
Other changes have been in using steel rather than nylon or polypropylene bolts to attach ceilings, steel angles, rivets and flashings over aluminium and the
introduction of profiled roofing Panel.
2.6 advantages of using isp
• Durability Panel has been proven to provide long term solutions see Photo 1 of patio made with roofing Panel after recent Cyclone Yasi.
• Easy to install, long spanning see Photo 2.
• Provides a good thermal envelope.
• Use minimal adhesives and sealants, reducing potential VOC’s.
• Light weight, low maintenance, recyclable and reusable.
• Uses non ozone depleting insulants.
Photo 1: patio made with solarspan after cyclone yasi
1.
Photo 2: panel being installed
2.
7
INTRODUCING A CODE OF PRACTICE
FOR EXPANDED POLYSTYRENE PANELS
IPCA Ltd.
Insulated Panel Council
Australasia Ltd
Formerly EPSA Inc. PMG
Version 1.0
2.7 WHere is isp used?
ISP were initially used for buildings such as cool stores, however as the benefits of using ISP have been become more widely know their use has been spread
to a variety of applications. They are often used in relocate able buildings and were used in construction of the 1988 World Exhibition Buildings in Brisbane,
after the exhibition was closed the Panels were re-used in constructing buildings in Australia, New Zealand and Asia. ISP will be found in a wide variety of
construction such as, animal housing, school halls, food production facilities and storage facilities.
2.8 fire requirements of the bca
2.8.1 changes to building code of australia
The Building Code of Australia (BCA) is constantly being reviewed and upgraded, on May 1, 2006 on the basis of recommendations from a working group
review 7; changes were made to the specification of fire hazard properties. Specifically the performance criteria for both wall and ceiling linings and floor
coverings, requiring fire testing to new test methods. Previously the fire hazard properties for internal linings (walls, ceilings and floors), were determined
from fire testing to AS 1530 Part 3 8. From 1st May 2006 the BCA introduced a separate specification for both wall and ceiling linings and floor coverings.
By the time this paper has been presented the BCA will have been upgraded again, to make this specification clearer.
2.8.1 bca fire indices requirements – as 1530.3 testing
AS 1530.3 is a small scale fire test that is called for in the BCA for materials other than (a) floor materials and floor coverings; and (b) wall and ceiling
linings. AS 1530.3 uses a vertically mounted radiant Panel facing a vertical sample to simulate the early development of fire in a building. The result of this
test is four separate indices as per Table 1, of the four indices only two are specifically referred to in the BCA specification as per Table 2.
Tabel 1: as 1530.3 indicies
Ignitability
0 –20
Spread of Flame
0 –10
Heat Evolved
0 –10
Smoke Developed
0 –10
Tabel 2: actual requirements for now sarking type material
A Spread-of-Flame Index not more than 9.
A Smoke-Developed-Index not more than 8 if the Spread-of-Flame Index is 5 or more.
Tabel 3: Actual isp and Comparative Product results
8
Ingnitability Index
Spread-of-Flame Index
Heat Evolved Index
Smoke-Developed Index
EPS Cored PAnel
0
0
0
1
Mineral Wool Cored Panel
0
0
0
3
PIR Cored Panel
0
0
0
1
EPS
10
0
2
5
PIR
16
0
0
5
Mineral Wool
0
0
0
0 –1
Plasterboard
12
0
2
3
Radiata Pine
15
5
5
3
BCA
N/A
9 (max)
N/A
8 (max)
INTRODUCING A CODE OF PRACTICE
FOR EXPANDED POLYSTYRENE PANELS
IPCA Ltd.
Insulated Panel Council
Australasia Ltd
Formerly EPSA Inc. PMG
Version 1.0
2.8.3 BCA GROUP numbers requirements – iso 9705
BCA Specification C1.10 16 provides a required Group Number for wall and ceiling lining materials, based on the Class of building, the location within the building,
and whether or not the building is sprinkler protected or not (Table 4). NOTE - For buildings not protected with a sprinkler system, a smoke growth rate of not
more than 100, or an average specific extinction area of less than 250m2/kg is required. There are two different ways the Group Number of a material may be
determined, firstly by a small scale test AS 3837 known as the cone calorimetry test or secondly by the ISO 970517 room test. The cone calorimetry test should
only be applied to non composite wall and ceiling lining materials, hence Sandwich Panels have to be evaluated by the ISO 9705 room test.
Tabel 4: wall and ceiling lining material (material groups premitted)
Class of Building
Fire-Isolated
Exits
Wall/Ceiling
Public Corridors
Wall
Specific Areas
Ceiling
Other Areas
Wall
Ceiling
Wall/Ceiling
Class 2 or 3
Excluding accomodation for the aged, people with disabilities and children
Unsprinklered
1
1,2
1,2
1,2
1,2
1,2
SPrinklered
1
1,2,3
1,2,3
1,2,3
1,2,3
1,2,3
1,2
1,2,3
Class 3 or 9a
Accomondation for the aged, people with disabilities and children and health-care buildings
Unsprinklered
1
1
Sprinklered
1
1,2
1
1,2
1,2,3
Class 5, 6, 7, 8 or 9b schools
Unsprinklered
1
1,2
1,2
1,2,3
1,2
1,2,3
Sprinklered
1
1,2,3
1,2,3
1,2,3
1,2,3
1,2,3
Unsprinklered
1
1
1
1,2
1,2
1,2,3
Sprinklered
1
1,2
1,2
1,2,3
1,2,3
1,2,3
1
1,2
1,2
1,2,3
1,2,3
1,2,3
Class 9b other than schools
Class 9c
Sprinklered
iso 9705 TEST
In the ISO 9705 test a room is built of the materials under evaluation, within another room. This construction is then subjected to heat in the form of a gas
burner placed in the far corner of the room with 100kW of energy for 10 minutes, and then 300kW of energy for 10 minutes. If the test specimen lasts the
full 20 minute test without flashing over (room bursting into flames), then it is classified as a Group 1 Material, if it last more than 10 minutes but less than
20 minutes, then it is classified as Group 2 Material. The Smoke Growth Rate Index is calculated by the amount of smoke given off during the test.
3.0 Literature review and code development
3.1 introduction
There has been a number of extensive literature reviews conducted into the performance of ISP in fire situations. The most relevant of these in relation to
the code are those which have focused on improving or reviewing the performance of ISP in fire and construction methods similar to those experienced
in Australia such as Collier & Baker 18; Griffin et Al 19; Baker 20; and Collier 21. International studies are relevant where they focus on the overall risk aspects
of ISP fires. The objective of this review is to outline the platform upon which the code has been based. There have been many other publications and
presentations concerning ISP, however many of these are not relevant to Australian conditions and regulations or focus on different outcomes than improved
installation and fire performance.
9
INTRODUCING A CODE OF PRACTICE
FOR EXPANDED POLYSTYRENE PANELS
IPCA Ltd.
Insulated Panel Council
Australasia Ltd
Formerly EPSA Inc. PMG
Version 1.0
3.2 Fire Incidents
One of the main impetus for development of the CODE were a number of large scale food processing facility fires 22, 23, where EPS cored ISP was one of the
building materials in use, resulting in total losses of buildings and content in Australia over the past 30 years. There have also been incidents overseas 24, 25
in which ISP have been the main building material of use in large scale fires. That ISP has been involved in large scale fires is no surprise as historically the
majority of cool stores and food processing plants have used EPS cored ISP due to desirable attributes such as good thermal properties, light weight, ease of
construction and low cost. The following are a series of summaries on some of the incidents which have occurred.
Care is required when interpreting past fire incidents, often the construction methods do not reflect current construction methods of ISP, or whilst EPS is
mentioned it is not present in the form of an ISP but has been installed in another manner. Generally most large fires have a long list of contributing factors
as to why the fire begun and how it came to be of the size it was, generally the use of ISP is low down on this list. This was the case in the Worcester MA
warehouse fire where six fire fighters died. This warehouse was not Code Compliant, had numerous deficiencies and Sandwich Panels were not a part of any
of the structure.
Whilst carbon based building materials such as wood and plastics will contribute to the base fire load, generally the contribution of the building contents
to the fire is more significant. This is demonstrated in fires such as that in Tamihere, NZ where large quantities of cheese fuelled a fire that followed
an explosion killing a firefighter, and although the building construction used ISP, it was not specifically implicated in contributing to the fatality 24. The
Atherstone on Stour, UK fire where four firefighters died was in a vegetable packing plant that reportedly also contained a PIR roof and subsequent concerns
were raised over possible breaches of health and safety laws by fire chiefs while directing the firefighting operations 27, 28, 29, 30, 31.
It is important to note that these are primarily processing facility fires that eventually involve the building construction. The fires would have occurred
regardless of the construction type. A large fire at a Greenacre meat processing facility in 2007 32, 33, highlights a number of issues concerning poor
performance of EPS cored ISP as well as other fire safety matters. Although the buildings concerned were largely traditional construction (e.g. steel portal
frame, brick walls, iron roof) there was extensive use of EPS cored ISP within the building envelope to subdivide the areas into processing, packaging and
storage rooms. There were no vents or skylights in the roof. The internal ceiling panels were suspended from the roof with metal cables, but nylon/plastic
fastenings that connected the ceilings to the cables failed in the fire and allowed large sections of ceiling to collapse. Some of the panels used aluminium
facings that melted in the fire. Delamination of the metal facings occurred in some areas exposing the combustible core material. Delamination occurs
between 150 -250˚C when the adhesive fails and is generally independent of the core material 5, 28.
The building was also reportedly a labyrinth of interconnecting processing rooms, cold stores, passageways, hall ways, doors and corridors, built via a series
of ‘add-ons’ over 36 years. Firefighting access was severely obstructed due to the presence of numerous processing equipment, machines, work benches,
trolleys, suspended ceiling racking, conveyor belts, stock and storage racking. A number of the characteristics of this building contributed to the poor
performance and are not representative of current or recent construction techniques.
The Sun Valley fire in a processing facility in Hereford, UK in which two fighter fighters lost their lives was an example where ISP (including EPS, Mineral
Wool and PU) were supported on a metal grid suspended from the roof and held in place with polypropylene fixing pins that subsequently failed in the fire 34.
The Sun Valley fire also an example of a practice that is no longer undertaken with new installations.
Many of case studies tend to involve food processing facilities where there are many potential ignition sources in the food processing areas 35. The presence of
ISP alone is not the determining factor in that stand alone cool stores are also considered low risk. Hence Risk Management is considered important – selecting a
suitable type of ISP for the risk is important rather than banning products outright where they have many practical advantages for different applications.
There do not appear to be published Australia statistics to review the number of fires in buildings constructed from EPS cored ISP in relation to other building
material types. What can be confirmed is that there have been no fatalities in commercial buildings constructed from ISP in Australia. A quote from the ABI
technical briefing sums it up the majority of findings best “Sandwich Panels do not start a fire on their own, and where systems have been implicated in fire
spread the fire has often started in high risk areas such as cooking areas, subsequently spreading as a result of poor fire Risk Management, prevention and
containment measures. Prevention of ignition and containment of early fire spread are critical. Specific and detailed risk assessment is crucial 5.
3.3 improvements to fixing methods
In response to both updated BCA ISO 9705 fire testing requirements and research18 reports which have shown the impact of fixings on Panel performance in
fire situation, the EPSA PMG conducted testing according to ISO 9705 on a EPS cored ISP with a variety of Panel’s thickness and fixing configurations36, 37.
The results of this testing clearly showed the importance of construction details on the resulting Group Number see Table 5. Group Numbers for EPS cored ISP
were limited by thickness, with the thicker the Panel the worse the performance and the type of material used for flashing off and fixing the Panels together.
Steel flashings lead to much improved performance and only their use can achieve a Group 1 Number as the aluminium melts and falls away at a much
lower temperature. This finding is confirmed by review of Group Numbers for Insulating Panels made with other core materials such as Mineral Wool, this only
achieves a Group 2 Number when using aluminium flashings and rivets as opposed to steel.
10
INTRODUCING A CODE OF PRACTICE
FOR EXPANDED POLYSTYRENE PANELS
IPCA Ltd.
Insulated Panel Council
Australasia Ltd
Formerly EPSA Inc. PMG
Version 1.0
Tabel 5: summary of group ratings for isp systems
Panel
Flashing
Rivets at 300mm Centres
Group Number
Smoke Growth Rate Index
250mm or less EPS Panel
Steel
Steel
2
<100
250mm or less EPS Panel
Steel
Steel Rivet at 120mm in
Ceiling Panel
1
<100
150mm or less EPS Panel
Aluminium
Aluminium
2
<100
150mm or less Mineral
Wool Core
Steel
Steel
1
<100
150mm or less Mineral
Wool Core
Aluminium
Aluminium
2
<100
Thus to be Code Compliant these construction details must be followed:
• No aluminium rivets all steel or stainless steel fixings.
• No aluminium extrusions to Panel junctions; all junctions to be steel of the equivalent thickness of the Panel skins minimum.
3.4 delamination
One of the key faults of ISP in fire situations, given they are often installed over long spans is the possibility of delamination occurring, the skins becoming
detached and becoming projectiles. Delamination of the core from the steel will occur at around the same temperature for all Insulated Panels types, as they
are all adhered with a polyurethane adhesive, either as it is made insitu or added on to the steel face. A variety of temperature ranges are quoted in the
literature 20, with Panels typically found to delaminate in below 270˚C 35.
3.5 FIRE Spread within PANEL
A major concern in fire situations has been that fire may spread within the Sandwich Panel unseen. Opinion has been divided as to whether fire spread
occurs in the growth stages of a fire and or once flashover has occurred and how much impact it has on the outcome of a fire. Research studies looking into
ways to improve the performance of EPS cored ISP 18 specifically investigated the subject of fire spreading within Panels with an EPS core. A 200mm by
200mm hole was cut in the 4,000mm (h) by 2,000mm (w), 100 mm thick EPS cored ISP and then a gas burner placed next to the hole. The EPS core of
the ISP melted and burned where the fire impinged on the Panel and stopped burning once the flame/heat source was removed see Photo 3. At a sufficient
distance from the fire source, unaffected EPS core remained.
These results have been confirmed by subsequent replicate testing commission by the EPSA Group, and testing by the CSIRO which found “there was no
evidence of fire spread within the cores prior to flash over” 19. Previous research 20 conducted by the University of Canterbury where a hot flue (max 800˚C)
was placed flush against EPS cored ISP, concluded that “flame-retardant EPS will not support self-sustaining fire spread in the insulated cavity of PIP when
the core is exposed to a direct radiant heat source”.
DIAGRAM 3: eps panel after direct exposure to 300Kw fire for 60 minutes
11
INTRODUCING A CODE OF PRACTICE
FOR EXPANDED POLYSTYRENE PANELS
IPCA Ltd.
Insulated Panel Council
Australasia Ltd
Formerly EPSA Inc. PMG
Version 1.0
3.6 ceiling support
The study into improved EPS cored ISP performance 18 also looked into the performance of ceiling suspensions using AS 1530.4 to evaluate the ability of ISP
to with stand a full scale fire from either below or above the suspended ceiling. In both cases the “suspension system proved to be more than adequate in
retaining a ceiling under fire resistance conditions”. A key outcome of this research is seen in this and other CODES in which it is mandated that ceilings be
installed with:
• Perimeter suspension to all ceilings - ceilings not to be supported by Panel walls.
•No nylon fixings or suspensions to be used; minimum 10mm galvanised steel or stainless steel threaded steel rod with either; wire and gripples, or
certified chain.
• Ceiling suspensions need to provide no failure after 30 minutes exposure to 300kW.
3.7 toxicity of isp in fire
An often cited concern is the “toxicity” of EPS when it is burning. EPS, being a carbon based material will undergo combustion when a fire has reached a
critical point, like all carbon based materials the products of combustion depending on the intensity of the fire and the level of oxygen available will be,
carbon dioxide, carbon monoxide, soot, and a variety of other carbon based chemicals 39. Generally the most toxic chemical emitted from fires is carbon
monoxide; the levels of this are directly related to the amount of oxygen available for combustion.
Burning EPS is considered no a more toxic hazard than wood materials 40, 41, 42. The black colour of the smoke from burning polystyrene is indicative of
the amount of unburned particulate material in the incomplete products of combustion building contents contribute to the smoke produced as well. Fires
in buildings with few external openings will burn inefficiently and produce more soot and particulate matter if there is insufficient air available to ensure
complete combustion of the fuel. Cool stores by their very nature have few external openings and therefore fully developed fires in those buildings are likely
to be strongly ventilation controlled and exhibit incomplete combustion.
3.8 risk reduction strategies
In all fires there needs to be a source of fire, it is the reduction of initial fire sources that should be the first focus of building owners and insurers, whilst
mitigating the impact of a fire when it occurs should be a focus of builders and product manufacturers this is addressed by the CODE. The CODE also
addresses and supplies supporting documentation for Risk Management Strategies with the post construction recommendations specifically:
• Inspection and maintenance procedures
• Risk Management Planning
• Issuing Safe Work Permits
• Issuing Hot Work Permits
3.9 panel identification
A concern to fire fighters when a fire is taking place is identification of the building material type. The CODE clearly addresses this concern through its Panel
Labeling requirements, and the process of certification. The entry doors to Code Compliant structures must have a label attached as per Appendix 4, notifying
people entering what they are made of and that they have been installed as Code Compliant, Key Diagrams of the buildings are to be kept in the fire
indicator Panel, this will inform interested parties as to the construction details of the building.
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4.0 Implementation of the code
4.1 History
Development of the CODE began in 2008 in response to industry concerns about ISP performance in fire situations. The focus of the CODE was on aspects
of building construction, manufacturers and installers of ISP have control over in relation to the structural performance in a fire situation. The EPSA PMG
acknowledges that other CODES1 cover a broader range of objectives and ISP types and that development of a broader scope longer term may occur.
Currently the focus is on implementing the CODE as it stands today to ensure the safety benefits for fire fighters and the general community are delivered
immediately.
4.2 SCOPE
• The intention of the CODE is to deliver a better performing Panel System in a fire.
• The CODE DOES NOT mitigate any requirements of the relevant building legislation.
• The CODE is not to be used in conjunction with a fire engineered alternative solution under the performance provisions of the Building Code of Australia.
• Design applications using the CODE as part of a building approval submission need to consult with the Fire Brigade having jurisdiction.
4.3 Objectives
Compliance with the CODE will achieve a more fire stable structure and fire fighter confidence in EPS-FR Panel Systems, through:
(a) Establishing minimum principles and standards for:
(i) The design specification and approval of facilities incorporating such systems.
(ii) The manufacture and installation of EPS-FR Panel used in such systems.
(b) Promoting strategies to address the risk of fire, as well as the maintenance requirements and emergency planning procedures in facilities incorporating
such systems.
(c) Providing recognizable “Code Branding Mark” that distinguishes EPS-FR Panel System that construction that is complaint with this CODE.
4.4 CODE SUMMARY
Whilst the CODE is voluntary in nature, certification that a project has been installed to CODE requirements is not. For a project to be Certified as Code
Compliant:
• Manufacturers and installers of Panel must be signatories to the CODE.
• An application for Certification of that the project is Code Compliant needs to be made to the EPSA Inc. PMG Code Facilitator, including an application
fee of $550. This application should include:
– Design and detailing specifications.
– Panel manufacture type.
– Panel installation details/drawings.
– Post construction recommendations.
– Identification/labelling requirements.
4.5 code specifics
4.5.1 design detailing and specification
Drawings for these details need to be submitted:
• Cross Sectional Drawing.
• Fixings of External Walls to Base.
• Fixing of External Wall to Insitu Floor.
• Load Out Area-External Wall Base Details.
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• Wall to Wall Corner Details.
• Ceiling Connection Chiller to Freezer.
• Wall to Ceiling with Hanging Fastener Details.
• External Wall and Low Ceiling Details.
• Intermediate Ceiling Suspension Details.
• Main Ceiling Suspension Details.
• Chiller Freezer Intermediate Wall Fixing Detail.
– Floor plan detailing locations for each Panel type.
– Number of doors and types of labels required.
– Total square metres of Panel to be installed.
– Existing Panel Certification number if an extension.
4.5.2 panel manufacturing/type
To meet minimum requirements Panel must be:
• Made with a minimum SL Grade FR- EPS Foam in accordance with AS1366.3-1992.
• Manufactured from 100% FR Bead.
• Microban® or equivalent anti-bacterial paint technology.
• Steel skins bonded to EPS core with two-part heat polymerising adhesive.
• Constructed from continuous laminating roll forming process providing interlocking tongue and groove style joints.
• Panel surface either smooth or standard style profiles.
4.5.3 panel installation
EPS-FR Panel will be installed to Group 1 BCA AS/ISO 9705 C1.10a and require the following enhancements:
• Support:
– Perimeter suspension to all ceilings (ends of panel not supported from wall panels).
– Minimum 10mm galvanised or stainless steel broker rods with either wire and gripples or certified chain.
– All steel junctions equivalent thickness to skins (no aluminium extrusions).
• Floor Insulation:
– FR- EPS in two staggered layers of equal thickness.
– One layer of heavy duty polythene film vapour proof membrane 0.25um thickness.
• Sealants:
– Vapour seal on “warm” side of Panel work.
– Non-setting mastic for -30°C to +50°C temperature range.
– Mastic applied as per Section 9.3.C of Code.
– White and mould resistant silicone in food processing areas.
• Fixings:
– All blind, sealed steel encased 4mm rivets.
– Class 3 steel screws.
– Rivets and/or screws at 300mm centres.
– Ceiling suspension and wall girt fixings as per section 9.3.D.
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• Joints:
– All joints designed and fabricated as per Section 9.3.E.
• Thermal Cuts:
– Provision has been made for expansion and contraction of Panel skins.
• Relief Ports:
– Provision for pressure relief using double acting multi - valve relief ports.
– Pressure relief ports fitted with Heater Cables.
– Heater Cables.
– Heater Cables are low voltage.
– Voltage regulated with a suitable circuit breaker.
• Doors:
– All doors are manufactured and installed as per Section 9.3.I of the Code.
– All doors fitted with safety escape instructions and release mechanisms.
4.5.4 post construction recommendations
These recommendations need to be supplied:
• Inspection and maintenance procedures.
• Risk Management Planning.
• Issuing Safe Work Permits.
• Issuing Hot Work Permits.
4.6 current signaturies of the code
The CODE has good industry support with over 80 % of industry signed up to the CODE.
4.7 barriers to code uptake
There are barriers to the uptake of the CODE as it is voluntary in nature. There will be costs involved with ensuring that the company involved in supply or
installation of ISP is accredited as Code Compliant and cost of construction may be marginally higher, due to then use of steel ceiling supports, steel flashings
and rivets etc. Ensuring the benefits of the CODE are well understood, working with all stakeholders, manufactures; builders; builder owners and occupiers;
fire and emergency services; insurers; ABCB, and Standards Australia will help overcome these barriers. When insurers, building developers, building owners
and fire services insist on building demonstrating Code Compliance uptake will be rapid.
4.8 long term plan
Implementation of the CODE began on 1st December 2010, EPSA Inc PMG will continue to support the Certification Scheme, conduct information sessions
where required and provide advice to new and current signatories on how to be Code Compliant. As discussed in the introduction the CODE is based
specifically on the fire performance of EPS cored ISP for Class 7 and 8 Buildings. Longer term goals may be to review the CODE for other BCA Classifications
of buildings and core types; and to review issues other than performance in fires situations such as vapour barrier sealing, hygiene and thermal performance.
EPSA PMG will continue with an experimental program to look at ways to improve the performance of Insulated Panels in a variety of configurations and
conditions. The environmental benefits of ISP have been touched on briefly in this report and may be the focus of future studies. EPSA PMG is also available
in terms of using their expertise in the expected performance of ISP in large scale fire when fire investigations are being undertaken.
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Version 1.0
5.0 summary
ISP have been growing in popularity as a building material over the past 20 years due to their ease of installation, light weight, long spanning properties and
many environmental benefits. There has been some concern over EPS cored ISP behaviour when the building it has been installed in is involved in a fire. The
CODE has been developed in response to these concerns and to provide fire fighters confidence of knowing; what a building is constructed of; that ceilings
are supported, steel flashing and rivets have been used; how it is expected to behave and the overall plan for the building.
The most important objective of the EPSA PMG in developing the CODE and working with the Fire Brigades directly was to address the concerns of the fire
fighters in relation to fires in buildings that have EPS cored ISP. As discussed in this paper, this led to the development, with the assistance of the NSW
Fire Brigade, of the CODE that will bring improvements to the EPS cored ISP. The CODE was presented to the Australian Fire Authorities’ Council (AFAC)
Built Environment Group for their review and information. As a result of this presentation, AFAC strongly supports the use of the CODE and has encouraged
and supported the industry for its proactive approach and agreed to further collaboration in future work on development of the CODE and research and
development to improve the fire performance of EPS ISP. This was evidenced in a three day research and testing workshop held in conjunction with the NSW
Fire Brigade, University of NSW, EPSMG and research scientists from China that was held at University of NSW on the 11th, 12th and 13th April.
5.1 CODE disclaimer and warning
It should be noted that the solutions in this voluntary Code of Practice (CODE) cannot guarantee safety or outcomes for occupants, fire fighters, or
owners of buildings in the event of a fire due to the unpredictable nature and behaviour of fire, and the many variables that affect fire behaviour which
are outside the control or influence of the recommendations of this CODE.
It is not the intention of EPSA Inc. or the EPSA Inc. Panel Manufacturers Group that this voluntary CODE be used as a guarantee of the products produced
or workmanship of the members and final jurisdiction and responsibility for fire performance rests with the relevant authorities and Code Compliant
Companies’ manufacturers and installers.
The accuracy and reliability of the content and recommendations should be independently confirmed by the reader.
Failure to implement proper Risk Management may result in loss, damage or injury and this voluntary CODE does not claim to cover every precaution
that is required to prevent the risk of fire in Insulated Panel Structures built in accordance with the CODE.
Expanded Polystyrene Australia Inc. will not accept liability as a result of acting on the content or recommendations of this publication or voluntary
Industry Code System.
“EPSA Inc. or EPSA Inc. Panel Manufacturers Group (collectively, EPSA) has made every attempt to ensure the accuracy, completeness and suitability of
the information presented in this CODE. Whilst every effort has been made to ensure accuracy, EPSA does not guarantee that the information is complete
or correct and no representation is made about the accuracy or completeness of the information and material and it should not be relied upon as a
substitute for the exercise of independent judgment.
EPSA will not be liable in any way whatsoever (including for negligence) for any loss, damage (including incidental, special or consequential damages),
costs or expenses suffered, arising out of, or in any way connected with the CODE to the extent permitted by law”.
© Expanded Polystyrene Australia Inc. ARBN 139 179 310
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Appendix 1: example of checklist requirements
Checklist Evidence Requirements
Please ensure you read the requirements of each of the following checklists and provide the information as specified.
Design, Detailing and Specification – Checklist
Documentary Evidence
Check that you have provided the following information with your application in regards to design detail:
Checklist – Panel System Designs and Details
Yes
No
N/A
Panels Systems Design Drawings:
Cross Sectional Drawing.
Fixings of External Walls to Base.
Fixing of External Wall to Insitu Floor.
Load out Area – External Wall Base Details.
Wall to Wall Corner Details.
Ceiling Connection Chiller to Freezer.
Wall to Ceiling with Hanging Fastener Details.
External Wall and Low Ceiling Details.
Intermediate Ceiling Suspension Details.
Main Ceiling Suspension Details.
Chiller Freezer Intermediate Wall Fixing Detail.
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Insulated Panel Council
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Appendix 2: example of risk management inspection form
Insulated Sandwich Panel Risk Management Inspection
Location (Area/Building/Floor) No:
Name of Inspecting Officer:
Signature of Inspecting Officer:
Date of this Inspection:
(DD/MM/YYYY)
Date of Previous Inspection:
(DD/MM/YYYY)
Storage and Housekeeping
Is internal storage of timber pallets, or packaging materials, within 5 metres of panels?
Do roof voids or other confined spaces contain combustible storage?
Is external storage of pallets, or waste bins, located within 10 metres of panel walls?
Was poor housekeeping or congestion evident in any of the areas inspected?
Was evidence of smoking noted in any of the areas inspected?
Was any evidence of unsafe storage or use of hazardous substances noted?
Are there any potential security or access issues or storage facilities that might
contribute to the structure being an easy target for an arsonist?
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Pass
Fail
ENTRY
FIRE
SERVICE
PANEL
COOKING
IPCA Ltd.
Insulated Panel Council
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EPS-FR = GROUP 1 CODE COMPLIANT
DRY STORE
RAW MATERIALS
CORRIDOR
Formerly EPSA Inc. PMG
EXISTING OFFICE
EXISTING
ISP TYPES
EPS/PH
THIS DRAWING IS THE PROPERTY OF EPSA INC.
AND IS RESTRICTED TO ITS OWN USE. THE WHOLE
OR ANY PART THEREOF MAY NOT BE COPIED OR
REPRODUCED OR LOANED IN ANY FORM WITHOUT
THE WRITTEN AUTHORISATION OF THE COMPANY.
PIR
DOCK/LOAD OUT
FINISHED GOODS
Client:
Project:
Title:
IPCA Ltd.
...
KEY DIAGRAM
MRF
FINISHED GOODS
PROCESSING/PACKING
N.T.S
Scale:
...
Checked:
16-9-10
Date Drawn:
...
By:
C.R
By:
EXISTING (NON ISP)
Sheet A3
PASSAGE
Sheet
1
Dwg. No:
Job No:
of
...
002.2011
...
...
Revision
BATTERY
CHARGE
PLANT
ELECTRICAL
BLAST FREEZER
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Appendix 3: example of key diagram
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INTRODUCING A CODE OF PRACTICE
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IPCA Ltd.
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Formerly EPSA Inc. PMG
Version 1.0
Appendix 4: example of labelling
3.0 LabelLing – For EPS - FR Core Type
PANEL IDENTIFICATION
PANEL GROUP: BCA C1.10
BCA Group
GROUP-1
CODE COMPLIANT: EPSA INC. PMG 001:2010
GROUP-1 PLUS
Code Compliant
Additional Measures
CORE TYPE:
EPS-FR
Core Type, see definition above
TESTED TO:
AS/ISO 9705
AS 1530 PT 3/A
Tested to Australian and International Standards
EPSA Inc.
CERTIFIED INSTALLATION
p +61 3 9429 0670
Panel Identification Label remains the property of EPSA Inc. and will be removed if not Code Compliant.
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INTRODUCING A CODE OF PRACTICE
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6.0 reference
Guidelines for the Design, Specification, Construction, Maintenance and Fire Management of Insulated Envelopes for Temperature Controlled Environments,
Second Edition, IACSC June, 2008.
2
Fire Risk Minimisation Guidance, Food Industry Panels Group, First Edition 2003.
3 Coldstore Engineering in New Zealand, IPENZ Practice Note 15, Version 1.0, IPENZ, June 2009.
4
CODE OF PRACTICE, (EPSA Inc PMG 0001:2010) Incorporating EPSA Inc. PMG Panel Certification Scheme Version 1.0, 2010.
5
Association of British Insurers; Technical Briefing: Fire Performance of Sandwich Panel Systems, May 2003, Partially Revised August 2008.
6 BondorPanel® Technical Data, SPAN TABLE - NON - CYCLONIC REGION A&B (WALL APPLICATIONS ONLY), SL Grade EPS Core/0.6mm Steel Skins
Maximum uniformly distributed ULS design wind load (kPa) for the given span, Bondor 14/02/11, 1:06 PM.
7
HBCD in Polystyrene Foams: Products Safety Assessment, HBCD Industry Working Group Submission to European Chemicals Agency (ECHA), April 2009.
8 CPIA, Fact Sheet Polystyrene Foam Insulation and Green Buildings, Flame Retardant Use and Safety, Canadian Plastics Industry Association.
9
Toxicological Risk of Fire Retardant Chemicals, National Academy of Sciences, National Academies Press, Washington DC, 2000.
10
AS 1366.3 -1992, Rigid cellular plastics sheets for thermal insulation - Rigid cellular polystyrene - Moulded (RC/PS - M), Standards Australia/Standards
New Zealand 1992.
11
Shipp .M .P; Morgan.P; Stirling.C; Jones.D; Malone.S; An initial review of the fire safety of large insulated sandwich panels, FRDG Publication No 3/97,
Home Office Fire Research and Development Group, May 1997.
12
Project Report FCRC PR 98- 02, Fire Performance of Wall and Ceiling Lining Materials, Final Report With Supplement, Fire Code Reform Research Program,
1999.
13
AS/NZS1530.3: 1999 - Methods for fire tests on building materials, components and structures - Part 3: Simultaneous determination of ignitability of
flame propagation, heat release and smoke release, Standards Australia 1999.
14
C1.10 FIRE HAZARD PROPERTIES - GENERAL, BCA 2007, Volume One, pps 151-153.
15
SPECIFICATION C1.10 FIRE HAZARD PROPERTIES - GENERAL, BCA 2007, Volume One, page 151.
16
SPECFICATION C1.10a FIRE HAZARD PROPERTIES - FLOORS, WALLS AND CEILINGS, BCA 2007, Volume One, page 156.
17
AS ISO 9750 Fire Tests - Full- scale room test for surface products, Standards Australia, 1993.
18
Collier.P; Baker.G; New Zealand Fire Service Commission Research Report Number 45, Improving the Fire Performance of Polystyrene Insulated Panel in
New Zealand, BRANZ April 2004.
19
Griffin.G.J; Bicknell.A; Bradbury.G.P; & White.N; Effect of construction method on the fire behaviour of sandwich panels with expanded polystyrene cores
in room fire tests; Journal of Fire Sciences Vol 24, No. 4, 275 -294, July 2006.
20
Baker.G; Performance of Expanded Polystyrene Insulated Panel Exposed to Radiant Heat; Fire Engineering Research Report 20002/1, University of
Canterbury, March 2002.
21
Collier.P.C.R, Flame Barrier of Foamed Plastic, Study Report No. 144 (2005), BRANZ, 2005.
22
Tip Top Bakery Fire, Fairfield Post Incident Summary Report, Post Incident Summary Report, PIA No.: 011/02, NSW Fire Brigade, Aug 02.
23
Wright.P; Post Incident Analysis & Fire Investigation Report WESTGATE COLD STORES DATE: 20.06.01; Fire Investigation & Analysis Unit MFB, 2001.
24
Beever.P; McGill.P; Henderson.P; Warner.S; New Zealand Fire Service, Inquiry into the Explosion and Fire at Icepak CoolStores, Tamahere, on 5 April
2008; Incident Number F128045: New Zealand Fire Service Commission, Wellington, New Zealand, September 2008.
25
Hefford.J; Fire Investigation Report for Ernest Adams LTD, 10 Print Place, CHCH Incident Number M074901 on 4 February 2000, New Zealand Fire
Service, 2000.
26
Anderson.J.R; Abandoned Cold Storage Warehouse Multi - Firefighter Fatality, USFA-TR-134, Fire US Department of Homeland Security, December 1999.
27
HSE Statement On Improvement Notice Served To Warwickshire Fire Service After Death Of Four Fire Fighters, UK, Press Report.
http://www.medicalnewstoday.com/articles/94429.php.
28
HSE finds fire service at fault over firefighter deaths. Press report, http://www.guardian.co.uk/uk/2008/jan/16/firefighters.haroonsiddique.
29
Dalton.A. J; Safety, Health and environmental hazards at the workplace, Page 30, Published by Cassell, 1998.
1
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31
32
33
34
35
36
37
38
39
40
41
42
22
Atherstone on Stour fire investigation, Warwickshire County Council Audit and Standards Committee -11 May 2010, Press Report May 2010.
Fire service bosses arrested over warehouse blaze that killed four, Press report, http://www.timesonline.co.uk/tol/news/uk/article7039387.ece.
New South Wales Fire Brigade, Case Study #1 Greenacre Twelfth Alarm Meat Processing Plant Fire, NSWFB Fire Operations Journal No. 3.
New South Wales Fire Brigade, Performance of Expanded Polystyrene Foam Insulated Sandwich Panel Structures Under Fire Conditions, NSWFB Fire
Operations Journal No. 3.
International Fire Consultants, Sun Valley Fire - Revisited, Report Undertaken for the British Plastics Federation.
Morgan.P; Shipp, M.P; Firefighting options for fires involving sandwich panels, Home Office Fire Research and Development Group, UK, 1999.
Wade.C.A; Collier.P.C.R; FAR 2277 Assessment of the Performance of the Metal Clad Expanded Polystyrene Sandwich in the AS ISO 9705 Room Fire Test,
BRANZ, July 2004.
Whiting.P.N; Collier.P.C.R; FAR 3323 Assessment of the Performance of the Expanded Polystyrene Panel Manufactures Group Roof Panel in the AS ISO
9705 Room Fire Test, BRANZ, July 2009.
Whiting.P.N; Collier.P.C.R; FM 4371, Adhoc Testing to Evaluate the Phenomenon of Fire Spread Within Polystyrene Insulated Panels, BRANZ, 14th May
2010.
Savolainen.H; Kirchner.N; Toxicological Mechanisms of Fire Smoke, the Internet Journal of Rescue and Disaster Medicine, Volume 1, Number 1, 1998.
Dowling.V.P; A survey of thermal decomposition of products of expanded polystyrene, Technical Report TR94/1; Division of Building, Construction and
Engineering, CSIRO, 1994.
BASF, Technical Information Styropor® 129 - Fire characteristics of Styropor foams, BASF Aktiengesellschaft Ludwigshafen, 2001.
Hertzberg.T; et al. Particles and isocyanates from fires -SP Report 2003:05, SP Swedish National Testing and Research Institute, 2003.
23
IPCA Ltd.
Insulated Panel Council
Australasia Ltd
Formerly EPSA Inc. PMG
phone: +61 7 3803 9388
mobile: 0419 644 924
email: ceo@insulatedpanelcouncil.org
web: www.insulatedpanelcouncil.org
C/- PO Box 1562
Browns Plains BC
Queensland 4118
IPCA Ltd.
Insulated Panel Council
Australasia Ltd
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Formerly EPSA Inc. PMG