Protection of Rack Stored Exposed Expanded Group A Plastics with ESFR Sprinklers and Vertical Barriers

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1 Protection of Rack Stored Exposed Expanded Group A Plastics with ESFR Sprinklers and Vertical Barriers Suppression, Detection and Signaling Research and Applications Conference SupDet 2015 March 5, 2015 Daniel R. Steppan Staff Engineer UL LLC UL and the UL logo are trademarks of UL LLC 2015

2 Fire Protection Research Foundation Project Team Sponsors IKEA Viking Sprinkler Reliable Sprinkler Tyco Fire and Building Products XL Insurance Property Insurance Research Group Procter & Gamble Zurich Target Aon Insurance Technical Panel Ken Linder, Swiss Re Rich Pehrson, Rep. International Fire Marshals Association Jason Huczek, Southwest Research Institute John Denhardt, Strickland Fire Protection Steve Wolin, Code Consultants, Inc. Matt Klaus, NFPA Staff Liaison UL LLC Project Contractor 2

3 Plastics Hazard Severity NFPA 13 Commodity Classification Class or Group Class I Class II Class III Class IV Class or Group Material Essentially non-combustible products in corrugated cartons on combustible pallets Class I products in slatted wooden crates, solid wooden boxes or multiple thickness paperboard cartons with or without pallets Wood, paper, natural fiber cloth or Group C plastics with or without pallets. May contain a limited amount (5% by weight or volume or less) of Group A or Group B plastics Class I, II or III commodities in corrugated cartons with appreciable amounts (5-15% by weight, or 5-25% by volume) of Group A plastics Cartoned Unexpanded Group A Plastic Exposed Unexpanded Group A Plastic Cartoned Expanded Group A Plastic Exposed Expanded Group A Plastic 3

4 Protection of Exposed Expanded Plastics Stored in Racks Figure

5 Protection of Exposed Expanded Plastics Stored in Racks General Criteria for Test Data to be Considered for Supporting Revisions to NFPA 13 Key Parameters: Large scale fire tests addressing a range of parameters: Maximum ceiling height Minimum design pressure Minimum aisle width Ignition location relative to sprinklers Key Acceptance Criteria: Number of operated sprinklers No sustained combustion at the outer edge of the ends of the main array and outer edges of the target arrays F (538 C) maximum 1 minute average steel temperature measured above the fire 5

6 Protection of Exposed Expanded Plastics Stored in Racks Approach Used Ceiling only protection with large K-factor ESFR sprinklers having an intermediate temperature rating Vertical barriers to mitigate horizontal fire spread 8 ft. aisle width Evaluated blocking of certain transverse flue spaces to simulate some potential conditions that may occur in the field 6

7 FIRE TEST NUMBER Test 1 Test 2 Test 3 Test 5 Test 6 Test 7 Test 8 July 9, July 13, July 18, October November June 8, June 19, Test Date , , Test Parameters Storage Type Double Row Rack Commodity Type Exposed Expanded Group A Plastic (Bagged Meat Trays on Hardwood Pallets) Vertical Barriers 16 ft. on center - Main Array (Non-combustible) 24 ft. on center - Main Array (3/8 in. plywood) 16 ft. on center - Main Array (Combustible 3/8 in. plywood) Number of Blocked Traverse Flue Spaces None Length of Main Storage Array, ft Nominal Storage Height, ft Ceiling Height, ft Aisle Width, ft. 8 Ignition Location Between 2 Sprinklers (offset) Under 1 Sprinkler (offset) Sprinkler Type ESFR Sprinkler Orientation Pendent Deflector to Ceiling, in. 14 Sprinkler Spacing, sprinkler by branchline ft. by ft. 10 by 10 Temperature Rating, F Nominal Sprinkler Discharge Coefficient K, gpm/psig 0.5 Nominal Discharge Pressure, psig Between 2 Sprinklers (offset)

8 Test 6 Arrangement Plan View Elevation View N 14 inches 10 ft. (typ.) C L 3/8 in. Plywood Vertical Barrier (typical) 8 ft. aisle 8 ft. aisle 3/8 inch plywood Vertical Barriers, 16 ft. on center Ignition - 2 half standard igniters 40 ft. 30 ft. nominal Exposed Expanded Group A Plastic (typical) Horizontal Barrier, Placed on top of pallets to span transverse flues (typical 60 positions) Ignition Location Vertical Barrier, 4 inches off of lab floor (typical) 8

9 Test 6 Camera Locations Ignition location: Centered under one sprinkler, offset in transverse flue space. 10 ft. (Typ.) N Spr 91 Spr 92 Spr 93 Spr 94 Spr 95 Spr 96 Spr 97 Spr 98 Spr 99 Spr ft. (Typ.) Spr 81 Spr 82 Spr 83 Spr 84 Spr 85 Spr 86 Spr 87 Spr 88 Spr 89 Spr 90 Spr 71 Spr 72 Spr 73 Spr 74 Spr 75 Spr 76 Spr 77 Spr 78 Spr 79 Spr 80 Spr 61 Spr 62 Spr 63 Spr 64 Spr 65 Spr 66 Spr 67 Spr 68 Spr 69 Spr 70 South Wall View Spr 51 Spr 52 Spr 53 Spr 54 Spr 55 Spr 56 Spr 57 Spr 58 Spr 59 Spr 60 Spr 41 Spr 42 Spr 43 Spr 44 Spr 45 Spr 46 Spr 47 Spr 48 Spr 49 Spr 50 Spr 31 Spr 32 Spr 33 Spr 34 Spr 35 Spr 36 Spr 37 Spr 38 Spr 39 Spr 40 Initial Ignition Location of South Target Array Spr 21 Spr 22 Spr 23 Spr 24 Spr 25 Spr 26 Spr 27 Spr 28 Spr 29 Spr 30 Spr 11 Spr 12 Spr 13 Spr 14 Spr 15 Spr 16 Spr 17 Spr 18 Spr 19 Spr 20 Spr 1 Spr 2 Spr 3 Spr 4 Spr 5 Spr 6 Spr 7 Spr 8 Spr 9 Spr 10 Infrared Camera View North East Corner Balcony Camera View 9

10 Test 6 View from NE Balcony 10

11 Test 6 Sprinkler Operations (11) 11

12 Test 6 View from South East Corner - Infrared 12

13 Test 6 Damage Assessment North Side of Main Array 40 ft. 30 ft. nominal South Side of Main Array Ignition Location Centered Under 1 Sprinkler Offset Centered on North Main Array 40 ft. 30 ft. nominal 13

14 Test 6 South Target Array Damage Assessment View from Outside Arrangement 40 ft. 30 ft. nominal 14

15 Test 6 Main North Array Damage 15

16 Test 6 Main South Array Damage 16

17 Test 6 South Target Array Damage View from Outside Arrangement 17

18 Transverse Flue Space Blocking 18

19 2013 Work: FPRF Technical Panel met and decided to fund test 7 to see if the removal of the transverse flue space blockers would reduce the number of operating sprinklers. A 1.5X safety factor is required in accordance with paragraph of NFPA 13, 2013 Edition. 19

20 FIRE TEST NUMBER Test 1 Test 2 Test 3 Test 5 Test 6 Test 7 Test 8 July 9, July 13, July 18, October November June 8, June 19, Test Date , , Test Parameters Storage Type Double Row Rack Commodity Type Exposed Expanded Group A Plastic (Bagged Meat Trays on Hardwood Pallets) Vertical Barriers 16 ft. on center - Main Array (Non-combustible) 24 ft. on center - Main Array (3/8 in. plywood) 16 ft. on center - Main Array (Combustible 3/8 in. plywood) Number of Blocked Traverse Flue Spaces None Length of Main Storage Array, ft Nominal Storage Height, ft Ceiling Height, ft Aisle Width, ft. 8 Ignition Location Between 2 Sprinklers (offset) Under 1 Sprinkler (offset) Sprinkler Type ESFR Sprinkler Orientation Pendent Deflector to Ceiling, in. 14 Sprinkler Spacing, sprinkler by branchline ft. by ft. 10 by 10 Temperature Rating, F Nominal Sprinkler Discharge Coefficient K, gpm/psig 0.5 Nominal Discharge Pressure, psig Between 2 Sprinklers (offset)

21 Test 7 Arrangement Plan View Elevation View N C L 3/8 in. Plywood Vertical Barrier (typical) 14 inches 10 ft. (typ.) 3/8 inch plywood Vertical Barriers, 16 ft. on center 8 ft. aisle 8 ft. aisle Ignition - 2 half standard igniters 40 ft. 30 ft. nominal Exposed Expanded Group A Plastic (typical) Ignition Location Vertical Barrier, 4 inches off of lab floor (typical) 21

22 Test 7 View from NE Balcony 22

23 Test 7 Sprinkler Operations (7) dno dno dno dno dno dno dno dno dno dno dno dno dno dno dno dno dno dno dno dno dno dno dno dno dno dno dno 1:07 1:02 dno dno dno dno dno dno 0:47 1:09 dno dno dno dno dno 1:28 0:57 1:02 dno dno dno dno dno dno dno dno dno dno dno dno dno COPYRIGHT dno 2015 UL LLC. ALL dno RIGHTS RESERVED. THIS dno DOCUMENT MAY NOT dno BE dno 23 dno

24 Test 6 Sprinkler Operations (11) 24

25 Test 7 Main North Array Damage 25

26 Test 7 Main South Array Damage 26

27 Early 2014 Work: FPRF Technical Panel met and decided to fund test 8 as a repeat of Test 3, to see if the removal of the transverse flue space blockers would reduce the number of operating sprinklers. A 1.5X safety factor is required in accordance with paragraph of NFPA 13, 2013 Edition. 27

28 FIRE TEST NUMBER Test 1 Test 2 Test 3 Test 5 Test 6 Test 7 Test 8 Test Date July 9, 2012 July 13, 2012 July 18, 2012 Test Results October 31, 2012 November 8, 2012 June 8, 2013 Length of Test, minutes June 19, 2014 First Sprinkler Operation Time, min:sec Last Sprinkler Operation Time, min:sec Number of Operated Sprinklers Peak Gas Temperature at Ceiling Above Ignition, F Maximum 1 minute Average Gas Temperature at Ceiling Above Ignition, F Peak Steel Temperature at Ceiling Above Ignition, F Maximum 1 minute Average Steel Temperature at Ceiling Above Ignition, F Ignition Time of Target Array, minutes:seconds 0:39 0:44 0:52 0:47 0:48 0:47 0:48 8:23 3:21 1:45 1:39 4:35 1:28 2: None None None 1:01 (North Target) 1:27 (South Target) None None Fire Travel to Extremities of Test Array Yes (East and West end of Main) Yes (West end of Main) No Yes (North Target Array Burned Through to Extremities) Yes (South Target Array Burned Through to Extremities) No No 28

29 Test 8 Sprinkler Operations (7) 29

30 Observations Exposed, expanded Group A plastics create a unique and substantial challenge to a fire sprinkler system due to the extraordinarily quick fire growth and horizontal flame travel potential. The sprinkler protection schemes investigated during this research initiative demonstrated the ability to control ceiling temperatures to a relatively low level (maximum one-minute average steel temperature was 134 F). Blocking of transverse flue spaces within the array created a challenging condition for sprinklers to attack the burning combustibles. Vertical barriers installed demonstrated ability mitigate horizontal fire travel within the array. 30

31 Discharge Committee Work: The second draft meeting of the full discharge committee was held at the end of June 2013, which finalized their positions on the revisions to NFPA 13, including the following language: 31

32 Proposed Revisions to NFPA 13 in First Draft for 2016 Edition Key Criteria in a New Section in Chapter 17 for the Protection of Rack Stored Exposed, Expanded Plastics Maximum storage height = 35 ft. Maximum ceiling height = 40 ft Minimum aisle width = 8 ft. Nominal K=25.2 Pendent ESFR intermediate temperature rated sprinklers Minimum design pressure = 60 psi Design area = 12 sprinklers (4 sprinklers on each of 3 branch lines) Minimum water duration = 60 minutes Minimum hose allowance = 250 gpm Maximum vertical barrier distance = 16.5 ft. Vertical barrier material = 3/8 in plywood, 22 gauge steel or equivalent Maximum area between vertical barriers and aisles = 124 ft 2 Vertical barrier to extend across longitudinal aisle to top of storage Commodity permitted to extend 4 inches beyond vertical barrier at aisle

33 Recent Work and Where Do We Go From Here: FPRF Technical Panel met and decided to fund test 9 and 10 as an attempt to look at a reduction in discharge pressure for a reduction in ceiling height. 30 psig flowing pressure for a maximum ceiling height of 30 ft. was selected to test. Tests were both successful in that it both had 7 operating sprinklers, keeping intact the 12 sprinkler design criteria. (A 1.5X safety factor is required in accordance with paragraph of NFPA 13, 2013 Edition). The technical panel and other interested parties had a teleconference on Thursday, November 13, 2014 to discuss the impact of the successful testing on the proposed language to the 2016 Edition of NFPA

34 FIRE TEST NUMBER Test 1 Test 2 Test 3 Test 5 Test 6 Test 7 Test 8 Test 9 Test 10 July 9, July 13, July 18, October November June 8, June 19, Oct. 28, Oct. 30, Test Date , , Test Parameters Storage Type Double Row Rack Commodity Type Exposed Expanded Group A Plastic (Bagged Meat Trays on Hardwood Pallets) Vertical Barriers 16 ft. on center - Main Array (Non-combustible) 24 ft. on center - Main Array (3/8 in. plywood) 16 ft. on center - Main Array (Combustible 3/8 in. plywood) Number of Blocked Traverse Flue Spaces None Length of Main Storage Array, ft Nominal Storage Height, ft Ceiling Height, ft Aisle Width, ft. 8 Ignition Location Between 2 Sprinklers (offset) Under 1 Sprinkler (offset) Sprinkler Type ESFR Sprinkler Orientation Pendent Deflector to Ceiling, in. 14 Sprinkler Spacing, sprinkler by branchline ft. by ft. 10 by 10 Temperature Rating, F Nominal Sprinkler Discharge Coefficient K, gpm/psig 0.5 Nominal Discharge Pressure, psig Between 2 Sprinklers (offset) Under 1 Sprinkler (offset) Between 2 Sprinklers (offset)

35 FIRE TEST NUMBER Test 1 Test 2 Test 3 Test 5 Test 6 Test 7 Test 8 Test 9 Test 10 Test Date July 9, 2012 July 13, 2012 July 18, 2012 October 31, 2012 Test Results November 8, 2012 June 8, 2013 June 19, 2014 October 28, 2014 Length of Test, minutes October 30, 2014 First Sprinkler Operation Time, min:sec Last Sprinkler Operation Time, min:sec Number of Operated Sprinklers Peak Gas Temperature at Ceiling Above Ignition, F Maximum 1 minute Average Gas Temperature at Ceiling Above Ignition, F Peak Steel Temperature at Ceiling Above Ignition, F Maximum 1 minute Average Steel Temperature at Ceiling Above Ignition, F Ignition Time of Target Array, minutes:seconds 0:39 0:44 0:52 0:47 0:48 0:47 0:48 0:47 0:53 8:23 3:21 1:45 1:39 4:35 1:28 2:28 1:24 1: None None None 1:01 (North Target) 1:27 (South Target) None None None None Fire Travel to Extremities of Test Array Yes (East and West end of Main) Yes (West end of Main) No Yes (North Target Array Burned Through to Extremities) Yes (South Target Array Burned Through to Extremities) No No No No 35

36 Test 9 Sprinkler Operations (7) 36

37 Test 9 Main North Array Damage 37

38 Test 9 Main South Array Damage 38

39 Test 10 Sprinkler Operations (7) 39

40 Test 10 Main North Array Damage 40

41 Test 10 Main South Array Damage 41

42 Recent Work and Where Do We Go From Here: A Tentative Interim Amendment (TIA) was submitted by James Golinveaux of Tyco Fire Protection Products and endorsed by Rich Pehrson of Pehrson Fire PC as follows: (Public comment closing date of April 17, 2015) 42

43 TIA 1165 dated February 18, 2015 NFPA 13-Proposed 2016 Edition Standard for the Installation of Sprinkler Systems TIA Log No.: 1165 Reference: , A and A Comment Closing Date: April 17, 2015 Submitter: James E. Golinveaux, Tyco Fire Protection Products 1. Revise section to read as follows: The minimum operating pressure shall be either 30 psi (2.0 bar) or 60 psi (4.1 bar) based upon the applicable storage and ceiling height for the installation as follows: a) 30 psi (2.0 bar) for storage heights up to 25 ft (7.6 m) with a maximum ceiling height of 30 ft (9.1 m) b) 60 psi (4.1 bar) for storage heights up to 25 ft. (7.6 m) with a maximum ceiling height of 40 ft (12.2 m). 43

44 TIA 1165 dated February 18, Revise section A to read as follows: A The Fire Protection Research Foundation conducted a series of full-scale fire tests at Underwriters Laboratories to develop protection criteria for the rack storage of exposed expanded Group A plastic commodities. The tests are documented in the report, Protection of Rack Stored Exposed Expanded Group A Plastics with ESFR Sprinklers and Vertical Barriers. The criteria for exposed expanded plastics are based on Tests 2, 3, 7 and 8 of the series, which investigated a 40 ft (12.2 m) ceiling with a range of storage heights. The tests used K-25.2 intermediate-temperature ESFR sprinklers with vertical barriers attached to the rack uprights at nominal 16 ft (4.9 m) apart. Vertical barriers of sheet metal and 3 8 -in. plywood were both investigated. In Tests 1 through 6, transverse flue spaces between commodities were blocked. Comparing the results of Test 6 with blocked transverse flue spaces and Test 7 with no blocking of transverse flue spaces, the number of operated sprinklers decreased from 11 to 7 and improved suppression of the fire. The criteria for exposed expanded plastics are based on Tests 9 and 10 of the series, which investigated a 30 ft (9.1 m) ceiling with a range of storage heights. The tests used K-25.2 intermediate-temperature ESFR sprinklers with vertical barriers attached to the rack uprights at 16 ft (4.9 m) (nominal) apart. Vertical barriers of 3 8 -in. plywood was investigated. 44

45 TIA 1165 dated February 18, 2015 Substantiation: The Fire Protection Research Foundation coordinated additional full scale fire tests at 30 ft ceilings for the protection of Exposed Expanded Plastic storage on racks. Previous testing by the Foundation demonstrated protocol for 40 ft. ceiling protection at a higher design pressure. This new 30 ft ceiling information was not available to the technical committee during the Annual 2015 cycle of the NFPA 13 document. The reduction of design pressure from 60 psi (the design pressure for 40 ft ceilings) to 30 psi is significant to the cost of the design and installation. 45

46 Protection of Exposed Expanded Plastics Stored in Racks Complete FPRF Report can be found at: Reports and Proceedings Suppression Applications Protection of Exposed Expanded Group A Plastics with ESFR Sprinklers and Vertical Barriers 46