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Palusol SW - 10 Years of Success

Palusol® SW, a ready-made sandwich product composed of Palusol fire-protection panels and high-density fiberboards, can be integrated into fire doors.
Palusol SW carries existing certification under ASTM (American Society for Testing and Materials) and BS (British Standard).

Presentation held by Mike van Geyn, A.Sc.T., at the Palusol Celebration September 22/ 23, 2016.
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Palusol SW - 10 Years of Success

  1. 1. 10 Years of Success! Palusol SW Fire Door Assemblies in North America. Mike van Geyn, A.Sc.T.
  2. 2. 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
  3. 3. Introduction Mike 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.
  4. 4. Short History of Palusol SW Product Development
  5. 5. 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.
  6. 6. 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
  7. 7. 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
  8. 8. 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
  9. 9. Fire Testing Methods used in North America
  10. 10. Fire Testing Methods Fire Test Standards Europe – 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
  11. 11. Fire Exposure All 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).
  12. 12. Furnace Temperature Measurement The 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).
  13. 13. Differences in Test Methods Door/frame test assembly orientation  Doors open towards fire for North America  Doors open away from fire for Europe Temperature 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 only Furnace Internal Pressure • Negative for Canada, Positive everywhere else
  14. 14. Hose Stream Test The 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.
  15. 15. Hose Stream Test Video
  16. 16. 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.
  17. 17. 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.
  18. 18. Post Fire Test Photo
  19. 19. Post Hose Stream test Photo
  20. 20. Post Hose Stream Test Photo
  21. 21. 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.
  22. 22. Certification Requirements for North America
  23. 23. 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 Palusol active ingredient bears UL certification. • A certification with Guardian Fire is also maintained for the gulf states market.
  24. 24. 3rd Party Certification Cont’d Certification 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.
  25. 25. 3rd Party Certification Cont’d Third 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.
  26. 26. Overview of the BASF SW Fire Doors in North America
  27. 27. 45 Minute Arch Doors
  28. 28. 45 Minute Arch Doors
  29. 29. 45 minute Full Door Glazing
  30. 30. 45 Minute Communicating Doors
  31. 31. 45,60 Minute Grooved Face
  32. 32. 60 Minute Stile and Rail Construction
  33. 33. 90 Minute Single Door, 5/8” Core
  34. 34. 45 minute Frame Drawing
  35. 35. BASF Licensing System Licensing 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.
  36. 36. Looking Forward Continued 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
  37. 37. Thank-You Mike van Geyn, A.Sc.T.