BS 8414-2:2005 test on a Kingspan Benchmark External Wall Insulation Prepared for: Kingspan Ltd. Carrickmacross Road Kingscourt County Cavan Ireland 7 September 2011 0578 Page 1 of 30
Prepared on behalf of BRE Global by Name Tom Lennon Position Principal Consultant Signature Authorised on behalf of BRE Global by Name S Howard Position Business Group Manager, Passive Fire Date 7 September 2011 Signature BRE Global Bucknalls Lane Watford Herts WD25 9XX T + 44 (0) 1923 664100 F + 44 (0) 1923 664994 E enquiries@breglobal.com www.breglobal.com BRE Global is not UKAS accredited to make opinions and interpretation. Any opinions and interpretations included as part of this report are clearly marked as such. 0578 This report may only be distributed in its entirety and in accordance with the terms and conditions of the contract. Test results relate only to the items tested. We have no responsibility for the design, materials, workmanship or performance of the product or items tested. This report does not constitute an approval, certification or endorsement of the product tested. This report is made on behalf of BRE Global. By receiving the report and action on it, the client accepts that no individual is personally liable in contract, tort or breach of statutory duty (including negligence). No third party has any right to rely on this report. Page 2 of 30
Contents 1 Introduction 4 2 Details of tests carried out 4 2.1 Description of substrate 5 2.2 Description of product 5 2.3 Installation of Specimen 5 2.4 Conditioning of the Specimen 5 2.5 Test Conditions 5 3 Test results 6 3.1 Temperature profiles 6 3.2 Visual Observations 6 3.3 Post test damage report 7 4 Reference 8 5 Figures 8 Page 3 of 30
1 Introduction The test method, BS8414 Part 2: 2005 [1] describes a method of assessing the behaviour of nonloadbearing external cladding systems, rainscreen overcladding systems and external wall insulation systems when applied to the face of a building and exposed to an external fire under controlled conditions. The fire exposure is representative of an external fire source or a fully developed (post-flashover) fire in a room, venting through an opening such as a window aperture that exposes the cladding to the effects of external flames. The specification and interpretation of fire test methods is the subject of ongoing development and refinement. Changes in associated legislation may also occur. For these reasons it is recommended that the relevance of test reports over 5 years old should be considered by the user. The laboratory that issued the report will be able to offer, on behalf of the legal owner, a review of the procedures adopted for a particular test to ensure that they are consistent with current practices, and if required may endorse the test report. All measurements quoted in this report are nominal unless otherwise stated. 2 Details of tests carried out Name of laboratory: Laboratory address: BRE Global Ltd. Bucknalls Lane, Garston, Watford, Hertfordshire, WD25 9XX Telephone No.: 01923 664000 Fax No.: 01923 664910 Test reference: 270772-1 Date of test: 6 th May 2011 Sponsor: Sponsor address: Kingspan Limited Carrickmacross Road Kingscourt, County Cavan, Ireland Sponsors Reference No.: Kingspan PO Number 4500124779 Method: Deviations: The test was carried out in accordance with BS8414-2:2005 None Page 4 of 30
2.1 Description of substrate The test specimen was installed onto face 4 of the BRE Global External Cladding Test Facility. This is a multi-faceted test facility constructed from structural steel, with concrete beams at floor levels onto which the test specimen was installed. 2.2 Description of system The system is designated by the client as Benchmark Figures 1a to 1e show the system during construction. The system prior to test is shown in Figure 2. The system as tested comprised four preassembled modules, two for each face of the rig. Each module consisted of 100mm thick PIR insulated KS1200CS sandwich panels with top hat rails affixed at vertical joints plus additional intermediate top hat rails. The rear (internal) face of the system was boarded out with Type F plasterboard. The front (exterior) face of the system comprised tiles fixed to the panels via horizontal aluminium rails affixed to the vertical top hat rails. A schematic of the system as built is shown in figure 3. 2.3 Installation of Specimen All test materials were supplied and installed by the sponsor. BRE Global was not involved in the sample selection process and therefore cannot comment upon the relationship between samples supplied for test and the product supplied to the market. 2.4 Conditioning of the Specimen As this was a dry system there was no requirement for curing or conditioning of any of the components. The test was undertaken within two weeks of completion of the test specimen. 2.5 Test Conditions Test Date: 6 th May 2011 Ambient temperature: 18.2 C Wind speed: < 0.1 m/s test undertaken indoors Frequency of measurement: Data records were taken at 1 second intervals. Thermocouple locations: Level 1 External Level 2 External Level 2 Cavity between tiles and sandwich panel Level 2 Centre of sandwich panel Level 2 Cavity between plasterboard and sandwich panel Level 2 Rear of plasterboard Figure 4 shows the locations and identification numbers of the thermocouples for the test specimen and also the references used to describe the system. Page 5 of 30
3 Test results 3.1 Temperature profiles Figures 5 to 10 provide the temperature profiles recorded during the test. Figure 11 shows the system during the test. Parameter Result T s Start Temperature 218 C t s Start time T max Time over 600 C 2:36 min:sec after ignition of the crib 692 C (level 2 external) 0:55 min:sec (level 2 external) 3.2 Visual Observations Table 1. Visual Observations Refer to Figure 4 for height references. Time (mins:secs) Description 0:00 Ignition 1:00 Crib well alight some black smoke visible. 1:24 Flames to top of crib. 1:43 Flash flaming around top of hearth. 2:35 Flames up to 3 tiles above hearth. 2:53 Flame height 1m above hearth. 3:50 have fallen on floor. 4:15 Intermittent flaming to 2m. 5:05 Intermittent flames to level 1 thermocouples. 5:28 Sound of tiles cracking. 7:56 Flame heights 2m. 10:15 Intermittent flaming to 3m. 10:50 Smoke emanating from top of rig. 11:37 Tiles removed above centre of hearth. Burning behind tiles. Page 6 of 30
Time (mins:secs) Description 14:07 Vertical flaming behind tiles above hearth to 3m. 15:17 Insulation falling out above hearth. 16:48 Tiles removed to 1m above hearth. 17:53 More tiles removed up to 1.5m 18:52 Burning internally to 3m, 4.5m on external face. 19:31 Crib starting to break down. 22:30 Fire barrier compromised at first floor level. 23:32 Extensive flaming above barrier. 23:19 Top hat rail from centre of lower main wall module falls off onto floor of test facility. 24:01 Flaming spread extends above test facility on main wall. 25:30 Crib collapse. 26:23 Loud bang heard. 27:07 Burning inside panel. 30:00 Flame spread above test facility on both main and wing wall. 30:00 Crib extinguished. 30:00 40:00 Continued flaming of the system. 3.3 Post test damage report 3.3.1 External Tile Facing The condition of the face of the system following the test is shown in Figures 12 and 13. Figures 14 and 15 show the extent and nature of the flaming once the crib had been extinguished and illustrate flame spread above the test facility. Page 7 of 30
3.3.2 Insulation Layer The condition of the panel insulation is shown in Figures 16 and 17. 3.3.3 Collapse 3.3.3.1 collapse - There was no substantial collapse of the system during the test. 3.3.3.2 Partial collapse - A number of the external tiles were removed and a section of the top hat channel section fell off during test. See figures 12 and 13. 3.3.3.3 No flaming droplets were observed during the test. 4 Reference 1. BS 8414-2:2005, Fire Performance of External Cladding s Part 2: Fire performance of external cladding systems - Test method for non-load bearing external cladding systems fixed to and supported by a steel frame, British Standards Institute, Chiswick, 2005 5 Figures Figures 1a to e. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Photographs of the system under construction Photograph of the system prior to test Schematic of the system as built Location and identification numbers of thermocouples used (schematic) Graph of external temperatures for level 1 from t s Graph of external temperatures for level 2 from t s Graph of cavity temperatures between tiles and panel for level 2 from t s Graph of sandwich panel temperatures for level 2 from t s Graph of cavity temperatures between panel and plasterboard for level 2 from t s Graph of rear of plasterboard temperatures for level 2 from t s Photograph of early stages of the fire test Schematic of external surface damage following the test Photograph of the condition of the external face following the test Page 8 of 30
Figure 14. Figure 15. Figure 16. Figure 17. Photograph showing continued flaming of the main face Photograph showing continued flaming of the wing face Photograph of charring of insulation following strip down Photograph of charring of insulation following strip down Page 9 of 30
Figure 1a. Connection of panels to test rig Page 10 of 30
Figure 1b. Insulated panels in place on test rig Page 11 of 30
Figure 1c. Fire barrier installed at floor levels Page 12 of 30
Figure 1d. Plasterboard to rear of test specimen Page 13 of 30
Figure 1e. Tiles fixed to brackets Page 14 of 30
Figure 2. prior to test Page 15 of 30
Figure 3. Schematic of the system as built Page 16 of 30
Level 2 TC legend 0.5m 0.5m 0.5m 0.5m 0.15m 0.45m 0.45m Level 2 see legend 1 2 3 4 5 6 7 8 Plasterboard set E Cavity between plasterboard and sandwich panel Centre of sandwich panel D C Level 1 External Only 1 2 3 4 5 6 7 8 Cavity between tiles and sandwich panel B 50mm external @ 2.5m & 5m A Combustion Chamber Figure 4. Location and identification of thermocouples Page 17 of 30
Temperature Degrees C 1000 900 800 700 600 500 400 300 200 100 0 Kingspan Panels 100mm panel with tiles -500 0 500 1000 1500 2000 2500 3000 3500 4000 Time in seconds L1-1 L1-2 L1-3 L1-4 L1-5 L1-6 L1-7 L1-8 Figure 5. Level 1 external temperatures Page 18 of 30
Temperature Degrees C 800 700 600 500 400 300 200 100 0 Kingspan Panels 100mm panel with tiles -500 0 500 1000 1500 2000 2500 3000 3500 4000 Time in seconds L2-1 50mm L2-2 50mm L2-3 50mm L2-4 50mm L2-5 50mm L2-6 50mm L2-7 50mm L2-8 50mm Figure 6. Level 2 external temperatures Page 19 of 30
600 Kingspan Panels 100mm panel with tiles Temperature Degrees C 500 400 300 200 100 0-500 0 500 1000 1500 2000 2500 3000 3500 4000 Time in seconds L2-1 Cav 1 L2-2 Cav 1 L2-3 Cav 1 L2-4 Cav 1 L2-5 Cav 1 L2-6 Cav 1 L2-7 Cav 1 L2-8 Cav 1 Figure 7. Level 2 temperatures within cavity between tiles and insulated panel Page 20 of 30
700 Kingspan Panels 100mm panel with tiles Temperature Degrees C 600 500 400 300 200 100 0-500 0 500 1000 1500 2000 2500 3000 3500 4000 Time in seconds L2-1 Ins L2-2 Ins L2-3 Ins L2-4 Ins L2-5 Ins L2-6 Ins L2-7 Ins L2-8 Ins Figure 8. Level 2 temperatures in centre of insulated panel Page 21 of 30
300 Kingspan Panels 100mm panel with tiles Temperature Degrees C 250 200 150 100 50 0-500 0 500 1000 1500 2000 2500 3000 3500 4000 Time in seconds L2-1 Cav 2 L2-2 Cav 2 L2-3 Cav 2 L2-4 Cav 2 L2-5 Cav 2 L2-6 Cav 2 L2-7 Cav 2 L2-8 Cav 2 Figure 9. Level 2 temperature in cavity between insulated panel and plasterboard Page 22 of 30
30 Kingspan Panels 100mm panel with tiles Temperature Degrees C 25 20 15 10 5 0-500 0 500 1000 1500 2000 2500 3000 3500 4000 Time in seconds L2-1 PB L2-2 PB L2-3 PB L2-4 PB L2-5 PB L2-6 PB L2-7 PB L2-8 PB Figure 10. Level 2 temperatures on unexposed face of plasterboard Page 23 of 30
Figure 11. Early stages of the fire test Page 24 of 30
Figure 12. Schematic of surface damage Page 25 of 30
Figure 13. Photograph of damage to system following the test Page 26 of 30
Figure 14. Photograph showing continued flaming of the main face Page 27 of 30
Figure 15. Photograph showing continued flaming of the wing face Page 28 of 30
Figure 16. Charring of insulation following strip down of system Page 29 of 30
Figure 17. Charring of insulation following strip down of system ==============REPORT ENDS============= Page 30 of 30