Chapter 30
British Regulations for Upholstered Furniture Combustion-Modified Polyurethane Foam Κ. T. Paul
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Rapra Technology Limited, Shawbury, Shrewsbury, Shropshire, United Kingdom In 1988, the UK introduced Safety Regulations which ultimately w i l l require that domestic upholstered furniture and mattresses w i l l meet and resist a cigarette test and that fabrics and f i l l i n g s w i l l resist specified flaming ignition sources. Polyurethane foams must also be of the specified as combustion modified types which in the UK include foams containing melamine and exfoliated graphite. I t i s nearly 20 years ago that the unacceptable f i r e behaviour of "modern" upholstered f u r n i t u r e became h i g h l i g h t e d i n the UK by F i r e Brigade reports of domestic f i r e s . This poor performance was blamed on the use of f l e x i b l e polyurethane (PU) foam upholstery and demands were made to ban PU foam or at l e a s t to i n s i s t on the use of flame retarded PU foam. The Home O f f i c e summary of UK f i r e s t a t i s t i c s f o r 1987(1) shows that although only about 18% of f i r e s occur i n occupied dwellings, these r e s u l t i n t y p i c a l l y three q u a n t i t i e s of f a t a l and non-fatal i n j u r i e s . The greatest single cause of f i r e s i n dwellings i s the unintentional misuse of cooking equipment (43%) but these r e s u l t i n r e l a t i v e l y few f a t a l i t i e s (10%) but a larger proportion of non-fatal i n j u r i e s (37%). In contrast, f i r e s i n i t i a t e d by smokers materials and matches together cause 18% of f i r e s i n dwellings but r e s u l t i n 51% of f a t a l i t i e s and 28% of non-fatal i n j u r i e s . F i r e brigade reports i n d i c a t e that a major proportion of f i r e s i n i t i a t e d by smokers materials and matches involves upholstered f u r n i t u r e , bedding or mattresses e i t h e r at the i g n i t i o n stage or are d i r e c t l y involved i n the rapid growth stages of the f i r e s Tables I and I I . The response to t h i s s i t u a t i o n i n the e a r l y 1970's was to set-up three major research programmes to investigate the f i r e performance of f u r n i t u r e and furnishings. These programmes, (2), (3), (4), not s u r p r i s i n g l y , produced s i m i l a r conclusions that the adverse f i r e behaviour of upholstered f u r n i t u r e and made-up beds 0097-6156/90/0425-O498$06.50/0 © 1990 American Chemical Society
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
30.
PAUL
Table I.
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499
Combustion-Modified Polyurethane Foam
Location of F i r e s i n UK 1977 93.4 51 14 8.9 2.1 1.8 15.5
Location of :Fire Occupied Buildings Dwellings Industrial Public Area* Hospitals Schools Others
1982 96.2 56.4 11.3 9.2 1.8 4.3 15.3
1987 104.1 63.2 10.8 10.9 1.7 4.3 16.2
354.0 Total No. of Fires 357.9 326.8 * Hotels, hostels, boarding houses, clubs, public houses, restaurants, places of public entertainment and shops.
Table I I . Cause
Causes of F i r e s and Casualties in Dwellings
No.
of Fires 1000's 1978 1988 19.4 23.6 4.1 4.0
No.
of F a t a l i t i e s
Non-f a t a l Injuries 1988 1978 3123 1545 685 526
No. of
1978 38 49
1988 63 77
6.2 4.0
198 192
255 122
859 895
1788 976
17.0
16.6
215
138
1292
1815
50.7
55.5
692
653
5117
8387
Cooking Matches 1 Smokers Materials Heating Other and Unknown
4.5 5.7
Total
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
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FIRE AND POLYMERS
arose because of easy i g n i t i o n by small everyday sources (cigarettes and matches) and rapid burning producing high rates of heat, smoke and t o x i c f i r e gas generation. Major contributory factors were the use of smoulderable and e a s i l y i g n i t a b l e f a b r i c s , melting f a b r i c s and f l e x i b l e PU foams. Recommendations were to use materials which d i d not smoulder, to use f a b r i c s which were not e a s i l y i g n i t e d by small flames, and to r e s t r i c t the amount of flammable materials used. The use of i n t e r l i n e r s and b a r r i e r f a b r i c s and foams was demonstrated and also the adverse e f f e c t s of using c e r t a i n types of flame retarded PU foams (previously demanded) with flammable f a b r i c s . The work (3) confirmed the correctness of the d e c i s i o n not to enforce the use of flame retarded PU foam and showed that although high r e s i l i e n c e PU foams and flame retarded PU foams themselves were more d i f f i c u l t to i g n i t e , t h i s advantage was often l o s t when they were used i n f u r n i t u r e as f a b r i c covered composites. E a r l y flame retarded PU foams were more l i k e l y to produce greater smoke and i n some circumstances could burn more r a p i d l y than composites containing standard PU foam. Various UK government a u t h o r i t i e s and e s p e c i a l l y The Crown Suppliers were already " f i r e conscious" and further extended the use of f a b r i c s of reduced flammability, b a r r i e r f a b r i c s and b a r r i e r foams, with high r e s i l i e n c e PU foams i n t h e i r purchase s p e c i f i c a t i o n s f o r upholstered f u r n i t u r e and bed assemblies f o r use i n the Crown Estate, p u b l i c b u i l d i n g s , h o s p i t a l s etc. T y p i c a l l y , products were required to meet c i g a r e t t e and No. 5 wooden c r i b sources see Table I when tested to Crown Suppliers Tests (5), (6). As B r i t i s h Standard t e s t s (7, 8, 9) f o r upholstered f u r n i t u r e i g n i t a b i l i t y became a v a i l a b l e , these were p r o g r e s s i v e l y used both by The Crown Estate and by government agency specifications. Home O f f i c e Codes of P r a c t i c e (10, 11) were gradually extended to a d d i t i o n a l p u b l i c areas and advised s i m i l a r i g n i t i o n performance to that o r i g i n a l l y used f o r p u b l i c areas, i . e . a minimum i g n i t i o n resistance of c i g a r e t t e and c r i b No.5 of BS 5852 Parts 1 and 2. A d d i t i o n a l codes have been added as they are prepared. The nett r e s u l t i s the upholstered f u r n i t u r e and bed assemblies i n the UK p u b l i c and government b u i l d i n g s are c o n t r o l l e d by a complex combination of Acts, Codes and Specifications. In essence these require that upholstered f u r n i t u r e r e s i s t s at l e a s t the c i g a r e t t e and small gas flame (No.l) i n low r i s k areas, the c i g a r e t t e and No.5 wood c r i b i n medium r i s k areas and the c i g a r e t t e and No.7 wood c r i b i n high r i s k areas. See Table I I I . These requirements have recently been published as B r i t i s h Standards (12) (13). In the UK, the p u b l i c sector has, since the e a r l y 1970's p r o g r e s s i v e l y introduced and formalised i g n i t i o n resistance performance s p e c i f i c a t i o n s f o r upholstered f u r n i t u r e , mattresses and bed assemblies e i t h e r on the product i t s e l f or on the upholstery composite. E a r l y t e s t s i n the mid 1970's f o r rate of f i r e growth were based on room-corridor t e s t r i g s i n which the product was burned to completion and f i r e temperatures, smoke density and volume and carbon monoxide concentration were monitored
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
285
2100
5
7
Wood c r i b
Woodcrib
SOURCE: Adapted from ref. 34.
660
510 725
725
890
880
35-40 140-150
2
12
1
2
-
-
Gas flame
°C
temp.
height
mm
Flame
Flame
16
KJ
Theoretical heat of combustion approx.
Gas flame
Cigarette
Parts 1 and 2
BS 5852
of
I g n i t i o n sources
49
20
20-40
30-40
-
2
kW/m
36g/min.
10g/min.
160 ml/min.
45 ml/min.
-
Rate o f burning
Local heat f l u x .
Table I I I . C h a r a c t e r i s t i c s o f I g n i t i o n Sources
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approx
approx
7 mins.
3 mins.
40 sees.
20 sees.
approx 20 mins.
-
flaming
of
Duration
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FIRE AND POLYMERS
continuously. Product s p e c i f i c a t i o n s were not issued but the t e s t s were used f o r comparative development and type approval t e s t s f o r c r i t i c a l i n s t a l l a t i o n s (5). The UK p u b l i c area s i t u a t i o n contrasted markedly with the UK domestic s i t u a t i o n . In s p i t e of the recommendations of the early research programmes, f u l l scale t e s t s with domestic f u r n i t u r e i n the l a t e 1970's showed, r e g r e t t a b l y , that not only had domestic upholstered f u r n i t u r e design and construction not followed the recommendations of e a r l y research, but that the f i r e performance of such f u r n i t u r e had arguably deteriorated. In 1978, the Home O f f i c e report (14) concerning the f i r e behaviour of new ( i . e . post 1945) materials s p e c i f i c a l l y c r i t i c i s e d the f i r e performance of upholstered domestic f u r n i t u r e and recommended manufacturers to improve i g n i t i o n r e s i s t a n c e , to reduce flammability, and to reduce the rates of smoke and t o x i c gas generation. In 1980 the Consumer Protection Act (15) required manufacturers to take reasonable steps to ensure that f a b r i c soft i n f i l l composites of domestic f u r n i t u r e r e s i s t e d the c i g a r e t t e t e s t of BS5852: Part 1. These regulations d i d not apply to rouchings, trims to seat platforms e t c . but only to the primary upholstery composites. The Consumer Protection Amendment of 1983 required s p e c i f i e d children's f u r n i t u r e containing c e l l u l a r materials had to r e s i s t Source 5 of BS 5852 Part 2. (16) The UK National Bedding Federation introduced a voluntary code which required i t s members only to manufacture mattresses which r e s i s t e d a smouldering c i g a r e t t e on i t s own and when covered by an i n s u l a t i n g , non-combustible f i b r e pad (17). This t e s t i s now defined within BS 6807(8) while BS 7175(18) r e f e r s to bedding and p i l l o w s . The 1988 Consumer Safety Regulations r e l a t e to both upholstered f u r n i t u r e and mattresses(19). I t i s not proposed to review the US s i t u a t i o n but i n some ways the UK s i t u a t i o n i s s i m i l a r to that i n the US with controls for domestic and p u b l i c area f u r n i t u r e but whereas the requirements apply throughout the whole of the UK, i n the US they are rather fragmented. The UFAC scheme and i t s d e r i v a t i v e s such as C a l i f o r n i a TB116 require upholstery composites to r e s i s t smouldering c i g a r e t t e s while other c i g a r e t t e t e s t s may be applied to upholstered f u r n i t u r e and mattresses. C a l i f o r n i a o r i g i n a t e d small flame i g n i t i o n requirements f o r PU foams f o r f u r n i t u r e (TB117) and also more severe and comprehensive t e s t s f o r high r i s k and p u b l i c occupancies (TBI33). The l a t t e r involve i g n i t i o n and s i m p l i f i e d smoke and carbon monoxide assessments. Boston also o r i g i n a t e d f i r e t e s t s f o r upholstery f o r some p u b l i c b u i l d i n g s i n c l u d i n g p r i s o n s , hotels e t c . A proposal which i s under consideration by various l e g i s l a t i v e s i s the International A s s o c i a t i o n of F i r e Fighters proposal which i s based on the C a l i f o r n i a n TB133 t e s t . The Underwriters Laboratories t e s t UL1056 i s based on the NBS f u r n i t u r e calorimeter and as such i s a much more comprehensive t e s t procedure. Other t e s t s are applied i n s p e c i a l environments e.g.
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
30. PAUL
Combustion-Modified Polyurethane Foam
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p r i s o n mattresses. US flame i g n i t i o n and flammability tests were received i n d e t a i l by Babraukas i n reference (20)(21).
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DEVELOPMENT OF FLAME RETARDED POLYURETHANE FOAMS(22)(23)(24) Early f l e x i b l e polyurethane foams were of the so c a l l e d standard type and were r e a d i l y i g n i t e d by a small flame. Once i g n i t e d they produced considerable amounts of heat and smoke. Flame retarded f l e x i b l e PU foams became a v a i l a b l e i n 1954-55, i . e . within a few years of f l e x i b l e PU foams becoming a v a i l a b l e i n commercial q u a n t i t i e s ( 2 2 ) . These FR PU foams contained t r i c h l o r o e t h y l phosphate or brominated phosphate esters and r e s i s t e d i g n i t i o n from small flame sources. Unfortunately they may burn when subjected to a larger i g n i t i o n source or when covered by a flammable f a b r i c and may then produce as much heat and more smoke than the standard grade of PU foam(3). This was i d e n t i f i e d by UK room t e s t s i n the e a r l y 1970's and has been confirmed more recently by f u r n i t u r e calorimeter t e s t s at the NBS(21). "Cold cure" or high r e s i l i e n c e PU foams tended to l i q u i f y before i g n i t i n g were developed and gave good r e s u l t s i n standard t e s t s such as BS 4735(25) (similar to the discontinued ASTM D1692) but could s t i l l burn when used with flammable f a b r i c s i n f u r n i t u r e (Table IV) . However they have been used most s u c c e s s f u l l y i n the UK i n combination with flame retarded cotton i n t e r l i n e r s and f a b r i c s of low flammability e.g. wool, nylon, FR cotton e t c . and formed the basis of p u b l i c area f u r n i t u r e used i n the UK since the e a r l y 1970's (Table V ) . A d i f f e r e n t approach was to impregnate standard PU foam with r e s i n bonded hydrated alumina. This material was o r i g i n a l l y developed as a f i r e b a r r i e r material and when used with high r e s i l i e n c e PU foams and f a b r i c s of low flammability gave upholstered seating and mattresses which r e s i s t e d the highest i g n i t i o n source of BS 5852 Part 2, the No.7 126 gram wood c r i b . The impregnated PU foam was subsequently developed f o r used as a f u l l depth mattress f o r p r i s o n and p s y c h i a t r i c h o s p i t a l use where vandalism and arson can be a problem but t h i s foam i s unsuitable for use i n upholstered chains e t c . The use of b a r r i e r f a b r i c s and foams were unacceptable to the UK domestic f u r n i t u r e industry which required single foam s o f t upholstery m a t e r i a l s . The flammability p r o p e r t i e s of the h y d r o p h i l i c PU foam developed i n USA i n the l a t e 1970's were outstanding even under severe f i r e conditions but i t ' s p h y s i c a l p r o p e r t i e s and high d e n s i t i e s r e s t r i c t e d i t s use f o r other than highly s p e c i a l i s e d high r i s k areas. The next major improvement was the development of combustion modified PU foam. The o r i g i n a l CMHR polyurethane foam was developed i n the USA (26) and contained hydrated alumina and halogenated flame retardants but was made i n a s i n g l e operation. It was used i n i n s t i t u t i o n s , p u b l i c b u i l d i n g s , hotels e t c . but i t s high density and less than optimum p h y s i c a l p r o p e r t i e s
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
mm/s
150
PC F l
PC F l
FC F l
PC F l
PC PI
Polypropylene
Cotton
Polyester
Wool
%10-20
1.6-4.2
Acrylic
covered PU foam
tests on f a b r i c
BS 5852 i g n i t i o n
Smoke Obscuration
PU foams
BS 5111 t e s t s on
Burn Date
Bum Distance mm
on PU foams
BS 4735 t e s t s
PU Foam
Standard
Table IV.
High
PC PI
PC PI
PC F l
PC F l
PC F l
21-42
1.4-2.2
24-41
PU Foam
Resilience
PC PI
PC PI
PC F l
PC F l
PC F l
49-53
0.9-1.8
93-125
PU Foam
FR A d d i t i v e
PC PI
PC PI
PC F l / T
PC PI
PC PI
PC F l / T
PC F l PC F l
PC F l / T
34-43
0.5-2.0
PC F l
94-96
0.5-0.6
10-30
(Melamine)
(A1/0H)3
31-38
PU Foam
Modified
Combustion
PU Foam
Modified
Combustion
foam f u r n i t u r e composites
I g n i t i b i l i t y of PU foams and f a b r i c covered PU
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PC PI
PC PI
PC F l / T
- -
PC F l
90-96
-
Graphite)
(Exfoliated
PU Foam
Modified
Combustion
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30. PAUL
505
Combustion-Modified Polyurethane Foam
Table V.
Fabric
Nylon Polyester Modacrylic FR PVC/Cotton Wool
I g n i t i b i l i t y of upholstery with Barrier Fabrics and Foams
Standard PU Foam
High Resilience PU Foam
Fl Fl
P1/F3 PI P3/4 P2/4 P5
-
P6 P2
High Resilience PU Foam & FR Cotton Barrier Fabrics P5 P5 P5 P5/ P5/6
High Resilience PU Foam & PU Barrier Foam P6 P6 P7 P7 P7
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
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FIRE AND
POLYMERS
r e s t r i c t e d i t s use f o r non-high r i s k a p p l i c a t i o n s . This type of material was a v a i l a b l e f o r a l i m i t e d p e r i o d i n the UK before being superceeded. This was followed both i n the UK and USA by a melamine containing high r e s i l i e n c e polyurethane foam. In the UK, the term combustion modified PU foam i s used f o r PU foams modified by the a d d i t i o n of melamine or e x f o l i a t e d graphite and as such d i f f e r s from the US use of the term. PU foams containing hydrated alumina i n the UK are prepared by a post impregnation process and are used as b a r r i e r foams and f o r i n s t i t u t i o n mattresses) which has improved p h y s i c a l p r o p e r t i e s when compared to the US Hypol and CMHR PU foams. In the UK polyurethane foams containing melamine or e x f o l i a t e d graphite are both r e f e r r e d to as "combustion modified polyurethane foam". These two foams are c u r r e n t l y a v a i l a b l e i n the UK and i t was the production of these materials which encouraged the next step towards improving the f i r e behaviour of UK domestic f u r n i t u r e since they permitted s i g n i f i c a n t f i r e behaviour improvements to be made without the use of b a r r i e r f a b r i c s and foams while using e x i s t i n g methods of f u r n i t u r e production. This i s a very important f a c t o r because the primary function of upholstered f u r n i t u r e , mattresses and bed assemblies i s to provide comfortable seating and support which i s hardwearing and durable as w e l l as a e s t h e t i c a l l y acceptable. The development of s u i t a b l e f a b r i c s , foams and other materials i s therefore of great importance and i s a factor that can be overlooked i n the p u r s u i t of improved f i r e performance. PRINCIPLE OF FURNITURE
1988
UK
REGULATIONS FOR
DOMESTIC UPHOLSTERED
Cigarette r e s i s t a n c e to BS 5852 Part 1 i s required by the primary upholstery composites of the a c t u a l f u r n i t u r e and mattress. This i s consistent with a l l previous UK regulations and s p e c i f i c a t i o n s which required that f i r e t e s t s should be c a r r i e d out on the a c t u a l upholstery composite. This p r i n c i p l e i s adhered to f o r flame i g n i t i o n t e s t s for the p u b l i c area which s t i l l requires that the t e s t s are c a r r i e d out on the upholstery composite although some s p e c i f i e r s are now r e q u i r i n g that a l l PU foam s h a l l a d d i t i o n a l l y comply with the 1988 Consumer Safety Regulations. The p r i n c i p l e of the 1988 Consumer Safety Regulations i s that a l l f i l l i n g materials and covering f a b r i c s s h a l l be i g n i t i o n r e s i s t a n t against s p e c i f i e d flames. An exception i s made for s p e c i f i e d types of f a b r i c which may be used with a flame retarded interliner. The 1988 Consumer Safety Regulations depart from the p r i n c i p l e of t e s t i n g composites because they e s s e n t i a l l y t e s t i n d i v i d u a l materials i n a standard manner although the composite BS 5852 t e s t i s used. Thus flame retarded f a b r i c s and i n t e r l i n e r s are tested with a s p e c i f i e d standard PU foam and polyurethane foams and other f i l l i n g s are tested with a s p e c i f i e d flame retarded polyester f a b r i c . I t i s understood that t h i s
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
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s i t u a t i o n a r i s e s because of i n d u s t r i a l requests and to s i m p l i f y the t e s t i n g of f a b r i c s and foams (note the c i g a r e t t e t e s t i s s t i l l c a r r i e d on the f u r n i t u r e composite).
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UK DOMESTIC FURNITURE AND THE CONSUMER SAFETY REGULATIONS 1988(19) The Consumer Safety Regulations 1988 regulations were recently published f o r domestic f u r n i t u r e and mattresses. These are a complex s e r i e s of r e l a t i v e l y simple i g n i t i o n t e s t s designed to r e s t r i c t the use of e a s i l y i g n i t a b l e f a b r i c s and i n f i l l m a t e r i a l s . The 1988 regulations replace the e a r l i e r regulations of 1980 and 1983. The Regulations apply to a l l types of upholstered seating, c h a i r s , sofa beds, sofas, settees, padded s t o o l s , f u r n i t u r e with padded areas (head boards), children's f u r n i t u r e , cots playpens, prams etc. garden f u r n i t u r e , caravan seating, mattresses, bed bases, scatter cushions and p i l l o w s . Furniture f o r export, second-hand caravans and f u r n i t u r e made before 1950 are excluded. Various parts of the regulations become e f f e c t i v e on d i f f e r e n t dates between 1st November, 1988 and 1st March, 1993 and the regulations require a l l f u r n i t u r e to be l a b e l l e d with the appropriate f i x e d and swing l a b e l s . This paper w i l l only deal with the f i r e t e s t s and not the time scale of i n t r o d u c t i o n or the l a b e l l i n g system (Tables VI, VII, and V I I I ) . PERMANENT COVERING FABRICS. These are e s s e n t i a l l y required to r e s i s t small flame i g n i t i o n and also to p r o t e c t covering f a b r i c s are therefore tested to i g n i t i o n source No.l, BS 5852 Part 1 (simulated match) over a standard PU foam. Should the f a b r i c not i g n i t e but merely melt to expose the standard PU foam, the l a t t e r w i l l i g n i t e and the f a b r i c w i l l f a i l the t e s t . Exceptions to t h i s are covering f a b r i c s which comprise at l e a s t 75% by weight of cotton, f l a x , viscose, modal, s i l k or wool and not coated with a PU system and which must be used with an i n t e r l i n e r . FR treated f a b r i c s must be pretreated by a s p e c i f i e d water soak t e s t (30 minutes at 40°C) to ensure that the treatments r e s i s t t y p i c a l household s p i l l a g e s etc. Loose covers are tested i n the same manner as the permanent covers but s t r e t c h covers s h a l l be tested with PU foam which meets the requirements of PU foam blocks and to i g n i t e source 5, Table VI. INTERLINERS. These are intended to protect the f i l l i n g against s p e c i f i e d flammable cover f a b r i c s . I n t e r l i n e r s are tested with i g n i t i o n source 5 over a standard PU foam to BS5852 Part 2. FR treated i n t e r l i n e r s s h a l l be subjected to the s p e c i f i e d water soak before t e s t i n g Table VI. ALL FILLING MATERIALS EXCEPT PU SHEETS OR BLOCKS. These are tested against i g n i t i o n source 2 which i s a butane flame, approximately 120 mm high and applied to the FR p o l y e s t e r f a b r i c covered f i l l i n g for 40 seconds(Table VII) to BS 5852 part 2. This applies to a l l loose foam and non-foam f i l l i n g when tested singly.
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Table VI.
Summary of Test Requirement for Fabrics
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Fabric
Cover fabric Loose covers Stretch covers Non-visible
Ignition Source to BS5852 1 1 1 1 5
Standard Test BS BS BS BS BS
fabrics
Interliners
5852/1 5852/1 5852/2 5852/2 5852/2
Test Modification Criteria A, B, D A, B, D C C B, D, Ε
A
Except for fabrics containing more than 75% by weight of cotton, f l a x , viscose, modal, s i l k or wool when used with an i n t e r l i n e r .
Β
With non-FR PU foam. 130, 20-22 kg/ m
BS
3379 Type Β hardness
Grade
3
3
C
With PU foam, 24-26 kg/m conforming to BS i g n i t i o n Source 5, 60g mass loss see T a b l e VII.
5852/2
D
With water soak for FR treated f a b r i c s .
Ε
Covered with the flame retarded polyester f a b r i c .
F
BS 5852 f a i l u r e c r i t e r i a of smouldering and of flame penetration through the specimen depth are waived, (clauses 4.1 e, 4.1 f and 4.9 f of BS 5852 Part 2).
G
Mass loss (mass loss through burning plus mass of drips f a l l i n g from test rig) s h a l l not be greater than 60 grams.
H
FR Polystyrene beads which consistently f a l l over and extinguish the gas flame are considered to have passed the t e s t .
The references A to H apply to Tables VI, VII, and VIII.
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30. PAUL
Table VII.
Summary of Test Requirements f o r F i l l i n g Materials - A l l Tested with Specified FR Polyester Fabric
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509
Combustion-Modified Polyurethane Foam
Failure Criteria
PU foam
BS 5852/2
Ignition Source to BS 5852 IS5
PU foam crumb
BS 5852/2
IS2
F
PS foam beads
BS 5852/2
IS2
H
Rubber latex
BS 5852/2
IS2
Non-foam f i l l i n g singly
BS 5852/2
IS2
Composite f i l l i n g s for other than mattresses bed bases, cushions, and pillows
BS 5852/2
IS2
Composite f i l l i n g s for mattresses and bed bases after removal of outer covering fabric
BS 6807
IS2
Standard Test
Note 1:
O r i g i n a l PU foam blocks to meet test f o r PU foam.
Note 2:
Pillows and cushions with primary covers and " s o l i d " or "loose" f i l l i n g s and tested as composites. See Table V I I I .
See f o o t n o t e s t o Table VI f o r e x p l a n a t i o n of c r i t e r i a .
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
F, G
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Table VIII.
Summary of Test Requirements for F i n a l Composite Assemblies
F i n a l Composite Assemblies Upholstered furniture Platform
composite
Mattresses*
Standard Test BS 5852/1 BS
9852/1
BS 6807*
Failure Criteria
Ignition Source to BS 5852 Cigarette Cigaret te
Cigarette (0) and Cigarette with non-combustible insulation (O/NS)
Pillows and cushions + BS 5852/2 with primary cover and non-loose fillings Pillows and cushions +# BS 5852/2 with primary cover and loose f i l l i n g s Not part of Consumer Protection Act but applied by UK industry as a voluntary code of p r a c t i c e . This w i l l be incorporated into the relevant B r i t i s h Standard and used to define "fitness for purpose." Cushions are covered by the s p e c i f i e d FR polyester fabrics. #
See
For loose f i l l i n g s , the test specified FR polyester f a b r i c . footnotes
to Table
r i g i s lined
VI f o re x p l a n a t i o n
of
with the
c r i t e r i a .
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
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PAUL
511
Combustion-Modified Polyurethane Foam
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When the non-foam f i l l i n g s are used as composite f i l l i n g s for upholstered seating or for mattresses and bed bases the multiple layer composite i s treated as a single material and tested i n i t s f i n a l form to BS 5852 part 2 or BS 6807 respectively. PU foam crumb must also have been made from PU foam block which meet the relevant requirements. Polystyrene foam beads are considered to have passed the t e s t i f the beads cascading from the specimen c o n s i s t e n t l y extinguish the gas flame (Table VII). POLYURETHANE FOAM SHEETS OR BLOCKS. These are required to r e s i s t i g n i t i o n source 5 (17 gram wood c r i b ) of BS5852 Part 2 except that the flames may penetrate the f u l l depth of the specimen and that the mass l o s s (due to burning and l i q u i d residues f a l l i n g from the t e s t r i g ) s h a l l not exceed 60 grams. These c r i t e r i a were developed by the UK PU foam industry and were intended to d i f f e r e n t i a t e the melamine or e x f o l i a t e d graphite containing combustion modified PU foams from the standard, high r e s i l i e n c e and flame retarded (chloro and bromo phosphate) containing PU foams (Table IV). This d i s t i n c t i o n was required because large scale burning t e s t s of r e a l arm chairs and furnished rooms had demonstrated the s u p e r i o r i t y of the combustion modified polyurethane foams. CIGARETTE TEST FOR UPHOLSTERED FURNITURE. Is c a r r i e d out with the f a b r i c (excluding braids and other trimmings but including seams), i n t e r l i n e r s i f used and f i l l i n g materials to BS5852 Part 1 using the c i g a r e t t e i g n i t i o n source. FR treated f a b r i c s are also subjected to the water soak pre-treatment (see i n t e r l i n i n g ) Table VI. This t e s t i s also applied to the platform composite i n a preposed modification to the r e g u l a t i o n . CIGARETTE TEST FOR MATTRESSES. Is c a r r i e d out using the f u l l composite to BS 6807 using the c i g a r e t t e (Source 0) and the c i g a r e t t e covered with the non-combustible, i n s u l a t i n g pad (Source O/NS). NOTE: These t e s t s are c u r r e n t l y part of a voluntary code and not part of Consumer Safety L e g i s l a t i o n but are part of the B r i t i s h Standard for Mattresses and w i l l be applied as a duty of care within the 1988 regulations. The No.l gas flame t e s t w i l l be introduced at the same time. FLAME IGNITION TEST FOR PILLOWS AND CUSHIONS WITH 'SOLID' FILLINGS. This i s c a r r i e d out using i g n i t i o n to BS 5852 Part 2, Source 2. Cushions are a d d i t i o n a l l y covered with the s p e c i f i e d FR polyester f a b r i c (Table VII). FLAME IGNITION TESTS FOR PILLOWS AND CUSHIONS WITH LOOSE FILLINGS. With primary covers and loose f i l l i n g s are tested to BS 5858 Part 2 with i g n i t i o n Source 2 using the s p e c i f i e d FR polyester f a b r i c l i n i n g to the t e s t r i g . Cushions are a d d i t i o n a l l y covered with the s p e c i f i e d FR polyester f a b r i c . TIMESCALE AND LABELLING. I t i s not proposed to deal with i n t r o d u c t i o n of l e g i s l a t i v e requirements i n d e t a i l but
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
the
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regulations are to be introduced over a period of time. Readers are strongly recommended to consult the Consumer Protection Act for d e t a i l s . Regulations for the PU foam f i l l i n g of manufactured items generally come into force on 1st November, 1988 f o r the sale of such items a f t e r 1st March 1989. Regulations for f u r n i t u r e intended for use i n the open a i r and for f u r n i t u r e f i x e d into caravans i s applied on 1st March 1990 and i s applied to second hand f u r n i t u r e on 1st March 1993. Furniture made before 1950 or materials for the reupholstery of such f u r n i t u r e are exempt from the regulations. The regulations require that f u r n i t u r e s h a l l be l a b e l l e d to indicate i t s conforming with various parts of the Act. Fire hazard warning labels are required as well as l a b e l s which i d e n t i f y the f u r n i t u r e , the person responsible for i t i n UK law (which may be the manufacturer or importer) as well as information r e l a t i n g to the composition of the f u r n i t u r e . The l a t t e r information may be on the l a b e l or may be retained by the company but must be a v a i l a b l e to Trading Standards O f f i c e r s for a period of 5 years. PROBABLE EFFECT OF FURNITURE
UK
CONSUMER REGULATIONS AND
FIRE HAZARDS OF
The f i r e hazards of upholstered f u r n i t u r e have been i d e n t i f i e d as easy i g n i t i o n by small sources such as c i g a r e t t e s and materials and rapid rates of generation of heat, smoke and t o x i c gases (2) (3) (4) . It i s therefore l o g i c a l to assess the UK regulations i n terms of these parameters. Upholstered f u r n i t u r e i s e s s e n t i a l l y a f i n i s h e d item but the flammability of bed assemblies i s markedly a f f e c t e d by a l l components. Bedding i s excluded from the regulations which apply only to p i l l o w s , mattresses and bed bases. CIGARETTE RESISTANCE. Trims, rouchings, and pipings (which are frequently c e l l u l o s i c ) are s p e c i f i c a l l y excluded from the c i g a r e t t e t e s t regulations for upholstered f u r n i t u r e . Because of t h i s , i t i s u n l i k e l y that the c i g a r e t t e t e s t requirement can ever r e s u l t i n upholstered f u r n i t u r e which i s completely c i g a r e t t e resistant. The platform which can be of a completely d i f f e r e n t construction to the primary upholstery and may be tested under a proposed modification to the regulations which include t e s t i n g " i n v i s i b l e " f a b r i c s to Source No.l over a PU foam r e s i s t i n g Source 5 to the 1988 r e g u l a t i o n . It has been demonstrated that a fabric/foam composite which passes the c i g a r e t t e t e s t of BS 5852 Part 1 can f a i l i f a s t r i p of viscose rouching i s placed along the junction of the v e r t i c a l and h o r i z o n t a l parts of the t e s t r i g . The paper of McCormack, Damant and Williams (27), describes the r e s u l t s of a t o t a l of 5619 t e s t s c a r r i e d out on 9 t e s t s i t e s on 450 upholstered c h a i r s . The overal number of i g n i t i o n s was 7.2% although i g n i t i o n on i n d i v i d u a l s i t e s v a r i e d from zero to 14.4%.
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
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513
It i s arguable that composites of the c r e v i c e , top of arm, top of back and smooth surface (34% of i g n i t i o n s ) are tested i n the crevice of BS 5852. The important areas of the welt, t u f t s etc. which includes piping and rouchings which gave 14.2% of i g n i t i o n are ignored. The platform (6.7% of i g n i t i o n ) i s tested separately. A s i m i l a r s i t u a t i o n e x i s t s f o r mattresses where BS 6807 section 4 s p e c i f i c a l l y excludes the t e s t i n g of edge piping, t u f t s , pleats e t c . The c i g a r e t t e i s used d i r e c t l y and also covered with a layer of non-combustible insulation representing non-smouldering bedding. The match t e s t (No.l gas flame) i s currently only applied to upholstered f u r n i t u r e but w i l l be applied to mattress i n the future by the same mechanism as the c i g a r e t t e t e s t . Defining the performance of f a b r i c s using a standard PU foam may produce a d i f f e r e n t r e s u l t (possibly superior) than t e s t i n g over the actual i n f i l l material to be used but w i l l create a s i m p l i f i e d system of t e s t i n g each f a b r i c at source. However, c i g a r e t t e t e s t s are c a r r i e d out using the actual composite and match resistance t e s t s at the same time as the c i g a r e t t e t e s t w i l l only add a few minutes to the t e s t and w i l l produce a t e c h n i c a l l y better r e s u l t . Although not included as part of the UK regulations, the revised BS 5852 w i l l include i g n i t i o n t e s t procedures f o r t e s t s on actual f u l l scale c h a i r s . F u l l scale i g n i t i o n t e s t s are already included i n BS 6807 for mattresses and bed assemblies. The use of match i g n i t a b l e covers over FR i n t e r l i n e r s i s p o t e n t i a l l y hazardous as flames can spread over r e a l f u r n i t u r e u n t i l a flammable item i s i g n i t e d and t h i s secondary source may then cause i g n i t i o n of the upholstery. Ignition resistant b a r r i e r fabric/HRPU foam composites have been widely used i n UK p u b l i c areas since the 1970's with f a b r i c s comprising wool, FR cotton, FRPVC e t c . to give composites which r e s i s t Source 5 of BS 5852 part 2. FR b a r r i e r systems have hardly ever been applied to domestic f u r n i t u r e i n the UK and i t i s i r o n i c that i t i s now acceptable because i t i s the only means of using c e r t a i n flammable f a b r i c s f o r domestic f u r n i t u r e . RATE OF BURNING AND USE OF IGNITION TESTS TO DEFINE FLAMMABILITY In an i d e a l s i t u a t i o n the parameters used to define f u r n i t u r e should be i g n i t i o n resistance and the rate of generation of heat, smoke and t o x i c gases. Tests to do t h i s with actual or mock-up f u l l sized f u r n i t u r e are not yet a v a i l a b l e as f i n a l s p e c i f i c a t i o n s but the Nordtest (28) and NBS f u r n i t u r e calorimeters (29) represent s c i e n t i f i c methods while room/ c o r r i d o r r i g s , t y p i c a l l y UK DOE PSA FR5 and 6 of 1976 (5)(6) were o r i g i n a l l y used but are l e s s s a t i s f a c t o r y from a s c i e n t i f i c point of view. The C a l i f o r n i a n (30) and Boston tests (31) f o r p u b l i c area f u r n i t u r e are e s s e n t i a l l y simple room t e s t s and are s i m i l a r in p r i n c i p l e to DOE, PSA, FR5 and 6 although the l a t t e r do not have p a s s / f a i l c r i t e r i a . Bench scale rate of heat release tests include the NBS cone (29) which, with a code of p r a c t i c e represent a p o s s i b l e a l t e r n a t i v e but the rate of burning of
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
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upholstered f u r n i t u r e i s markedly a f f e c t e d by design factors as well as by the f a b r i c s and f i l l i n g s used. A recent paper characterises the rate of release of PU foams using the OSU calorimeter (32). In the absence of a r e a d i l y a v a i l a b l e Standard rate of f i r e development t e s t , the UK f u r n i t u r e regulations have used high i g n i t i o n resistance as an a l t e r n a t i v e . Although s c i e n t i f i c a l l y d i f f e r e n t from rate of burning (33) , high i g n i t i o n resistance may be a r e a l i s t i c a l t e r n a t i v e for the next few years. The use of a high i g n i t i o n resistance f i l l i n g i n conjunction with a flammable f a b r i c i n a composite implies that the i g n i t i o n source r e p l i c a t e s or simulates a burning f a b r i c or other covering. If this philosophy were to be followed to i t s l o g i c a l conclusion, then each and every i n f i l l should be tested i n the same way and to the same source. A l t e r n a t i v e l y , q u a l i t y assurance type t e s t s may be used i n which p a s s / f a i l c r i t e r i a and t e s t conditions have been developed to d i s t i n g u i s h between materials known to have acceptable and unacceptable burning behaviour. This approach has been used i n the UK regulations and a considerable amount of f u l l scale test data i s a v a i l a b l e concerning PU foam f i l l e d f u r n i t u r e . Data for cotton wadding and cotton wadding/PU foam are also a v a i l a b l e e s p e c i a l l y from USA. Information concerning polyester f i b r e and polyester fibre/PU composites i s less r e a d i l y a v a i l a b l e but l i m i t e d data indicates that polyester f i b r e s (probably r e s i n bonded) burn i n a s i m i l a r manner to PU foams with a s i m i l a r o v e r a l l f i r e hazard. The use of simple, non-hazard r e l a t e d t e s t data to d i s t i n g u i s h between "good" and "bad" materials i s p o t e n t i a l l y hazardous because the t e s t performance has been determined by current materials. Because the t e s t s are simple, cheap and can be c a r r i e d out i n a small fume cupboard, there i s a strong p o s s i b i l i t y that future materials w i l l be developed to meet the small scale tests and w i l l not be evaluated i n hazard based t e s t s . This p o s s i b i l i t y could r e s u l t i n f u r n i t u r e of increased f i r e hazard. A further d i f f i c u l t y with small scale t e s t s i s that the r e l a t i v e f i r e performance and even the rank order of materials can change with d i f f e r e n t f i r e environments. Small scale tests can r a r e l y r e f l e c t r e a l l i f e f i r e s i t u a t i o n s and examples already e x i s t where r e l i a n c e on small scale t e s t s has l e t to hazardous f u l l scale s i t u a t i o n s . The p a s s / f a i l c r i t e r i a of BS 5852 Part 2 have been a l t e r e d for c e r t a i n materials to exclude clauses l i m i t i n g the extent of penetration of flaming or smouldering combustion. A maximum mass loss c r i t e r i a i s introduced for PU foam and i s e s s e n t i a l l y a means of d i s t i n g u i s h i n g between combustion modified and other types of PU foam. In p r a c t i c e , combustion modified PU foam i s l i k e l y to improve the burning behaviour of upholstered f u r n i t u r e . Although i t i s arguable that the Consumer Safety Regulations are based on t e s t procedures which are s c i e n t i f i c a l l y unsound and that they contradict the e s s e n t i a l s of composites t e s t i n g and hazard based f i r e t e s t s , large scale hazard based t e s t s involving the newer types of combustion modified PU foams with suitable f a b r i c s have shown
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s i g n i f i c a n t improvements i n f i r e behaviour. The time to rapid burning of a settee or c h a i r may be increased from 3 - 4 minutes to up to 10-30 minutes by the c a r e f u l combination of flame retarded f a b r i c s or f a b r i c s of inherently low flammability with combustion modified PU foams. The subsequent rates of heat release may be s i g n i f i c a n t l y reduced(21). Clearly this represents a major improvement although a f i r e problem can s t i l l exist. Complementary measures, e.g. the i n s t a l l a t i o n of smoke alarms w i l l be advantageous because they w i l l detect the small i n i t i a l f i r e i n i t s e a r l y stages. Although the i g n i t i o n resistance of upholstered f u r n i t u r e , mattresses and bed assemblies are s p e c i f i e d by t e s t s on the f i n a l composite specimen, f i l l i n g materials and foams are a d d i t i o n a l l y required to conform to the 1988 regulations (Table IX) . RATE OF BURNING TESTS T e c h n i c a l l y the recent UK regulations may be viewed as a short term measure pending the development of proper hazard based rate of f i r e development t e s t s . Considerable research has been published by Babrauskas (29) and others i n USA and also by workers i n Scandinavia (25) concerning the measurement of rates of f i r e development of f u l l scale f u r n i t u r e (furniture calorimeter and Nordtest hood/duct) while s i m i l a r research i s being c a r r i e d out i n the UK by F i r e Research S t a t i o n . The C a l i f o r n i a n TB133(30) approach does not measure fundamental parameters such as rate of heat release but i s a r e l a t i v e l y simple approach to l i m i t i n g the rate of f i r e growth of upholstered f u r n i t u r e . The NBS cone calorimeter (29) and OSU calorimeter (32) are being developed as a means of measuring rates of heat and smoke generation, as bench scale t e s t s . However, considerable evidence e x i s t s that the design of upholstered f u r n i t u r e has an important e f f e c t and that materials other than the primary upholster, e.g. viscose rouchings and trims, platform materials, e t c . can not only a l t e r the i g n i t i o n resistance but also the mechanisms and rates of burning. At present the only r e a l l y s a t i s f a c t o r y method of determining the rates of heat and smoke release from upholstered f u r n i t u r e and bed assemblies i s to burn the actual items. The implications of specimen s i z e , cost and complexity of t e s t equipment has so f a r l i m i t e d these to type approved t e s t s f o r c r i t i c a l a p p l i c a t i o n s . A p o s s i b l e s o l u t i o n would be to use a bench scale t e s t to eliminate the more hazardous composite but, depending on the outcome of current research, i t may s t i l l be necessary to use the f u l l scale hood t e s t approach (Nordtest) to i n d i c a t e safety. SUMMARY AND CONCLUSIONS 1)
The Consumer Protection, Furniture and Furnishings (Fire) (Safety) Regulations 1988 i s a complex a p p l i c a t i o n of a s e r i e s of i g n i t i o n t e s t s based on BS 5852 Parts 1 and 2 and BS 6807.
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Table IX.
Ignition Test Requirements f o r upholstered Furniture and Mattresses f o r UK
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Upholstered Furniture BS 5852
Low Hazard
Medium Hazard
High Hazard
Very High Hazard
Ignition
Cigarette •
Cigarette •
Cigarette •
At d i s c r e t i o n of
Source
No.l gas flame
No.5 wood c r i b s
No.7 wood c r i b s
specifier
Domestic Dwellings Colleges
Hospitals
Hospitals Hostels
Prison C e l l s Locked
Public Houses & Bars Public H a l l s
Schools Offices
Theatres, Cinemas e t c Restaurants Public Buildings
Sleeping
Psychiatric
Accommodation
Units
Offices Mattresses BS 6807
Section 4
Section 2
Section 2
DOE FTS 15
Mattress Section 3
Mattress Section 3
Vandalised Mattress
Bed Assembly
Bed Assembly
Cigarette
Cigarette
Cigarette
Cigarette • NC cover
No.l gas flame
No.l gas flame
No.5 wood c r i b
No.l gas flame No.7 wood c r i b
Domestic Dwellings
Public Buildings Halls of Residence at colleges Hostels Hotels
Dimensions
of test
Dimensions o f T e s t Specimen Width o f back H e i g h t o f back Width o f base Depth o f f i l l i n g
4 χ No. 7 Wood Cribs
Certain
Prison C e l l s
Hospitals Psychiatric
Locked p s y c h i a t r i c
Accommodation
Accommodation
Hotels Hostels
specimens BS 5852 P t . 1 (mm) 450 300 150 75
BS 5852 P t . 2 (mm) 450 450 300 75
BS 6807 (mm)
450 75
-square
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
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30. PAUL
517
Combustion-Modified Polyurethane Foam
2)
Actual upholstered composites are required to r e s i s t the c i g a r e t t e source of BS 5852 Part 1 ( f u r n i t u r e ) . Mattresses are also required to r e s i s t the c i g a r e t t e t e s t uncovered and covered with non- combustible i n s u l a t i o n o f BS 6807.
3)
The match (No.l gas flame) source of BS 5852 Part 1 i s only applied to upholstered f u r n i t u r e f a b r i c s over a standard PU foam although exceptions are made f o r c e r t a i n f a b r i c s , when used with FR i n t e r l i n e r s . It may also be applied to mattresses to BS 6807.
4)
A l l f i l l i n g materials are s p e c i f i e d by i g n i t i o n t e s t s to BS 5852 Part 2 and composite non-PU foam mattress f i l l i n g s to BS 5852 Part 2 and BS 6807 f o r seating and mattress a p p l i c a t i o n s r e s p e c t i v e l y with a flame retarded p o l y e s t e r fabric. D i f f e r e n t i g n i t i o n sources, constructions and p a s s / f a i l c r i t e r i a are used to d i f f e r e n t i a t e between "acceptable" and "unacceptable" m a t e r i a l s .
5)
"Acceptable" combustion modified PU foams have v a l i d a t e d i n f u l l scale hazard based f i r e t e s t s .
6)
The 1988 UK Regulations w i l l probably be e f f e c t i v e f o r upholstered f u r n i t u r e and mattresses comprising a high proportion of PU foam.
7)
Combining i g n i t i o n r e s i s t a n t f a b r i c s with combustion modified PU foam w i l l s i g n i f i c a n t l y improve the f i r e performance of upholstered f u r n i t u r e and mattresses.
8)
The actual composites used f o r upholstered f u r n i t u r e and mattresses i n government and p u b l i c b u i l d i n g s are required to meet c i g a r e t t e and c r i b 5 (for general use) and c r i b 7 for use i n high r i s k areas to BS 5852 Part 2 and BS6807. Combustions modified PU foam meeting the 1988 regulations i s a d d i t i o n a l l y l i k e l y to be required although these are outside the outside the 1988 regulations.
8)
Because of the lack of s u i t a b l e standard rate of heat, smoke and t o x i c gas generation t e s t s , the 1988 UK regulations are based on i g n i t i o n resistance of i n d i v i d u a l m a t e r i a l s . This contradicts the basic requirements f o r the f i r e t e s t i n g of composites and of hazard r e l a t e d t e s t s and as such i t may be p o s s i b l e to develop materials which meet the requirements but which produce hazardous products.
9)
The 1988 Regulations should i d e a l l y be replaced by performance requirements based on composite specimens tested by hazard r e l a t e d t e s t s e.g. rate of heat and smoke release when they become a v a i l a b l e .
been
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FIRE AND POLYMERS
LITERATURE CITED 1. 2.
3. 4. 5.
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6. 7.
8.
9.
10.
11. 12. 13. 14. 15. 16. 17.
18.
19. 20. 21. 22. 23. 24. 25.
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Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.
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RECEIVED
January 11, 1990
Nelson; Fire and Polymers ACS Symposium Series; American Chemical Society: Washington, DC, 1990.