Urethane Chemistry and Applications - ACS Publications - American

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Downloaded by UNIV OF CALIFORNIA SANTA BARBARA on September 21, 2016 | http://pubs.acs.org Publication Date: November 30, 1981 | doi: 10.1021/bk-1981-0172.ch009

Future Impact of Reduced Fire Hazards on Urethane Foam JOHN G. SCHUHMANN Urethane Chemicals TS&D, The Dow Chemical Company, Freeport, TX 77541

Today science is judged equally for its perceived technical merit and social effect. In reality, however, negative effects are easily measured while positive effects normally are not noted or recordable. For example, society has begun to label urethane foams as a fire hazard. Proper management of this fire issue may be one of the most influential factors in future urethane technology and market opportunities. Variables that must be considered in assessing fire risk in upholstered furnishings will be examined in this paper. Standards that have been established will be summarized and future standards and testing will be discussed. Background Entering the '80s the fire problem is well defined. We know the extent to which furniture and sleeping products are involved in fires, but have not been able to specifically identify the role of urethane foam involvement. Unmodified urethane foam can be ignited by open flames and burn rapidly. Modified urethane foams, however, are more ignition resistant. Most importantly, overall fire risk involves three important elements: l) the material ignited, 2) occupancy, and 3) the ignition source. Variance in these three interrelated factors will influence potential fire risk (Figure l ) . Apart from these technical considerations, of course, fire risk is an emotional issue. Measuring the value of human life and the social effects of fire are highly abstract and remain the most difficult hurdles in establishing fire risk criteria. This paper will attempt only to describe the technical variables of assessing fire risk. Knowing the technical elements illustrated in Figure 1, a fire hazard expert can reconstruct a fire event. The overall fire problem then is assessed by the number and magnitude of those individual fire events. For example, residential fires accounted for 95% of a l l structural civilian fatalities in 1977· About one-quarter of that group started with furniture and 18% 0097-6156/81/0172-0101$05.00/0 © 1981 American Chemical Society Edwards et al.; Urethane Chemistry and Applications ACS Symposium Series; American Chemical Society: Washington, DC, 1981.


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w i t h s l e e p i n g products. In f u r n i t u r e - r e l a t e d f i r e s , c i g a r e t t e i g n i t i o n s caused ten times as many f a t a l i t i e s as small open flame i g n i t i o n s . For mattresses, the r a t i o i s 5:1· Clearly, c i g a r e t t e - r e l a t e d a c c i d e n t s are preeminent i n f i r e f a t a l i t i e s c l a s s i f i e d " r e s i d e n t i a l " occupancy In e v a l u a t i n g f i r e s t a t i s t i c s , i t i s important to recognize that these numbers are e x t r a p o l a t e d from only a few recorded a c t u a l cases. For i n s t a n c e , the Consumer Product Safety Commiss i o n (CPSC) r e p o r t on upholstered f u r n i t u r e f l a m m a b i l i t y shows a t o t a l of only three f a t a l i t i e s recorded f o r upholstered f u r n i ture f i r e s i n i t i a t e d from open-flame sources f o r the s t a t e s of C a l i f o r n i a and Ohio i n 1977· A s i n g l e m u l t i - f a t a l i t y f i r e c o u l d d r a m a t i c a l l y change those numbers as happened i n 1976. That year only one f i r e was coded as o r i g i n a t i n g from a match or lighter. The urethane i n d u s t r y has a keen i n t e r e s t i n a l l t h i s a c t i v i t y because a l o t o f f l e x i b l e urethane foam goes i n t o upholstered f u r n i t u r e and bedding made today. A very high percentage of urethane foam goes i n t o products where strong codes are now i n p l a c e . About 70% of the f i r e s are i g n i t e d and more than 95% of the f a t a l i t i e s occur i n the r e s i d e n t i a l market which represents 83% of the t o t a l volume. Most a u t h o r i t i e s r e l a t e t h i s high f a t a l i t y p r o f i l e to the l a c k of p u b l i c awareness o f f i r e hazards (Figure 2). The f o l l o w i n g two l i m i t e d s t u d i e s dispute the assumptions that h a l f these upholstered f u r n i t u r e r e l a t e d f i r e deaths i n v o l v e d urethane foam. These s t u d i e s a l s o r e f l e c t the s i g n i f i c a n c e of a n a l y z i n g the f i r e problem from a composite perspective rather than by simply evaluating the components individually. One f e d e r a l study r e p o r t s 185 random i n c i d e n t s i n which u p h o l s t e r e d f u r n i t u r e was the f i r s t item to i g n i t e . In that study the N a t i o n a l Bureau of Standards T e x t i l e Chemists coded the composition of inner l a y e r s u b s t r a t e s . Seven percent were coded as urethane and 13% were combinations of c e l l u l o s i c and urethane m a t e r i a l s . The r e p o r t a l s o shows o n l y 50% of the outer f a b r i c s weighed more than 20 oz. per yard w h i l e 95% weighed 12 oz. per yard. Approximately 90% of the f a b r i c s were c e l l u l o s i c . In a d d i t i o n , n e a r l y 90% o f the f u r n i t u r e i n c i d e n t s were coded " c i g a r e t t e i g n i t e d . " The prominent r o l e s of c i g a r e t t e i g n i t i o n and c e l l u l o s i c f a b r i c i n f a t a l scenarios i s apparent i n t h i s study. In a second study, o n l y about 6% of the f i r e s recorded s t a r t e d i n occupied p a t i e n t rooms where urethane foam might be a c o n t r i b u t o r to f i r e spread. According to the study o f f i r e s i n 75 Massachusetts h o s p i t a l s , 11% were i n unoccupied areas where urethane foams c o u l d not be r u l e d out. However, kl% of the f i r e s s t a r t e d i n areas where urethane foam would not normally be present. In t h i s case, upholstered f u r n i t u r e w i t h urethane components probably d i d not play a s i g n i f i c a n t r o l e i n t h i s i n s t i t u tional f i r e setting. Edwards et al.; Urethane Chemistry and Applications ACS Symposium Series; American Chemical Society: Washington, DC, 1981.


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Urethane Foam

Occupancy

Ignition Source

Institutional 2%

Material Ignited

Open Flame 8%

Figure 1. Interrelatedflammabilityconsiderations.

13.9% Figure 2.The 1978 occupancy percentages/use of urethane foam.

Edwards et al.; Urethane Chemistry and Applications ACS Symposium Series; American Chemical Society: Washington, DC, 1981.


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These s t u d i e s and a d d i t i o n a l data suggest that generic banning o f urethane foam w i l l not solve the problem s i n c e the v a r i a b l e s are numerous and complex. Tools to assess component, composite and o v e r a l l system performance w i l l be needed. Based on these c r i t e r i a some urethane m a t e r i a l s w i l l be accepted w h i l e others w i l l not be marketed. Developing r e l i a b l e assessment c r i t e r i a has progressed s i g n i f i c a n t l y and w i l l continue to do so during the '80s. A d e t a i l e d c o n s i d e r a t i o n o f the f o l l o w i n g key v a r i a b l e s i n r i s k assessment w i l l help to set the stage f o r d i s c u s s i o n o f f u t u r e standards work. Variables:

I g n i t i o n Source

A c i g a r e t t e i g n i t i o n t e s t requirement f o r mattresses has e x i s t e d s i n c e 1973 i n the U.S. The CPSC has s t u d i e d the e f f e c t i v e n e s s o f t h a t t e s t and confirmed a d e f i n i t e r e d u c t i o n i n f a t a l i t i e s a t t r i b u t e d to c i g a r e t t e i g n i t e d f i r e s over the f o u r year e x i s t e n c e o f the standard. Mattresses c o n t a i n i n g f l e x i b l e urethane foam meet the requirements of t h i s c i g a r e t t e i g n i t i o n t e s t ( F i g u r e 3)· T h i s r a p i d s t a t i s t i c a l response i n reducing mattress smoldering f i r e l o s s e s i s g r a t i f y i n g . Yet there i s controversy about whether the improvements were caused by the standard or by p u b l i c education. "Learn Not to Burn" and other e d u c a t i o n a l programs developed by the N a t i o n a l F i r e P r o t e c t i o n A s s o c i a t i o n and the S o c i e t y o f the P l a s t i c s I n d u s t r y (SPl) seem to have been i n s t r u m e n t a l i n i n c r e a s i n g p u b l i c awareness o f f i r e hazards. These should be recognized as e f f e c t i v e t o o l s to help the g e n e r a l p u b l i c prevent and respond to f i r e s . The other type o f i g n i t i o n source considered i n s e t t i n g standards i s the open flame. To date the f e d e r a l government has not taken a c t i o n to set standards to reduce the r i s k o f open flame i g n i t i o n . However, i n d u s t r y has demonstrated i t can establ i s h e f f e c t i v e f i r e t e s t i n g and standards i n l i e u of f e d e r a l codes. T h i s has a l s o been accomplished i n c i g a r e t t e smoldering standards. The Upholstered F u r n i t u r e A c t i o n C o u n c i l (UFAC) designed i t s own proposal e s t a b l i s h i n g a national industry v o l u n t a r y program of f u r n i t u r e c o n s t r u c t i o n standards. Thus, i n d u s t r y has produced upholstered f u r n i t u r e that i s more r e s i s tant to c i g a r e t t e i g n i t i o n than i n the past. The progress o f t h i s UFAC program suggests that the CPSC w i l l have no reason to r e g u l a t e because i n d u s t r y w i l l have accomplished and exceeded the f e d e r a l o b j e c t i v e s . At the s t a t e l e v e l , C a l i f o r n i a has been the l e a d e r i n handl i n g the f i r e problem. This s t a t e r e q u i r e s a l l f l e x i b l e urethane foams used i n f u r n i t u r e to be flame r e t a r d a n t ( i . e . , to pass a v e r t i c a l open flame t e s t and smolder r e s i s t a n t screening as set f o r t h i n the t e s t requirement o f the C a l i f o r n i a Bureau o f



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105

Home F u r n i s h i n g s B u l l e t i n 117)· This s t a t e has been s u c c e s s f u l i n a c t i n g on the f i r e problem p r i m a r i l y because C a l i f o r n i a i s r e q u i r e d by s t a t e law to take that s p e c i f i c approach toward flame r e s i s t a n c e u n l i k e the CPSC which i s under general Cong r e s s i o n a l order to reduce f i r e deaths and l o s s e s . In summary, c i g a r e t t e smoldering and open flame are the two types o f i g n i t i o n considered i n a s s e s s i n g f i r e r i s k . Federal c i g a r e t t e standards are i n place f o r the mattress i n d u s t r y . Industry has been the leader i n c i g a r e t t e i g n i t i o n t e s t i n g f o r furniture. An e f f e c t i v e open flame standard has not been accepted, but i n d u s t r y and s t a t e governments are working toward that g o a l . Variables:

Occupancy

Three primary occupancy c l a s s i f i c a t i o n s are used i n f i r e r i s k assessment : r e s i d e n t i a l , i n s t i t u t i o n a l and commercial. The Urethane D i v i s i o n o f the SPI r e c e n t l y conducted an examinat i o n o f a l l major areas i n which f l e x i b l e urethane foams are used. In June, 1979 they reported : " C o m b u s t i b i l i t y performance standards f o r products i n which f l e x i b l e polyurethane foams, or other combust i b l e m a t e r i a l are used should vary a c c o r d i n g to types of occupancies and c e r t a i n other end use c o n d i t i o n s . " This means t h a t performance standards f o r c e r t a i n h i g h r i s k areas (such as penal and medical i n s t i t u t i o n s , places o f p u b l i c assembly and mass t r a n s p o r t a t i o n ) should be d i f f e r e n t than those for r e s i d e n t i a l or p r i v a t e t r a n s p o r t a t i o n . In high r i s k areas a g r e a t e r chance of open flame i g n i t i o n e x i s t s whether a c c i d e n t i a l or i n t e n t i o n a l . Other problems i n these areas i n c l u d e l i m i t e d m o b i l i t y and high r a t i o s of occupancy. N o n - r e s i d e n t i a l f i r e i n c i d e n c e s may be few but they are o f t e n s i g n i f i c a n t i n s e v e r i t y and are h i g h l y v i s i b l e events. They represent a major t h r u s t f o r f u t u r e standard research. Variables:

C o n s t r u c t i o n and F a b r i c

The f u r n i t u r e i n d u s t r y i s a l s o adapting to address the problems presented by f a b r i c and c o n s t r u c t i o n i n the f i r e r i s k of u p h o l s t e r e d f u r n i t u r e . S p e c i f i c a l l y they are t r y i n g to improve c i g a r e t t e smoldering r e s i s t a n c e i n f u r n i t u r e . The dilemma o f the f u r n i t u r e i n d u s t r y i s the overwhelming customer appeal o f c e l l u l o s i c f a b r i c s , though these f a b r i c s represent s i g n i f i c a n t f i r e r i s k around c a r e l e s s l y handled c i g arettes. In comparison, most common s y n t h e t i c f a b r i c s are p o o r l y r a t e d i n customer appeal even though they may be a s o l u t i o n to the c i g a r e t t e i g n i t i o n problem.



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Many f u r n i t u r e manufacturers have chosen to r e t a i n c e l l u l o s i c f a b r i c s and meet UFAC standards by changing c o n s t r u c t i o n design. Upholstered f u r n i t u r e c o n s t r u c t i o n can be complex. Some design requirements d i c t a t e d i f f e r e n t s e a t i n g and back constructions. Block forms are predominantly urethane foam c o n s t r u c t i o n ; q u i l t e d o r designed backs are u p h o l s t e r e d by a f i b e r p a c k i n g technique. Reducing f i r e hazard p o t e n t i a l i n b l o c k urethane seat cushions would mean a s i g n i f i c a n t c o n s t r u c t i o n a d a p t a t i o n f o r the f u r n i t u r e i n d u s t r y . The q u i l t e d or designed back c o n s t r u c t i o n , on the other hand, would r e q u i r e a simple component replacement. U n f o r t u n a t e l y , because upholstered f u r n i t u r e manufacturers are wood and u p h o l s t e r y s p e c i a l i s t s , they regard foam to be the l e a s t important. The c o n v e n t i o n a l cushion c o n s t r u c t i o n used precut foam w i t h a f a b r i c c o v e r i n g . Some manufacturers choose to add a garnetted f i b e r f i l between the foam and f a b r i c c o v e r i n g for a p l u s h look and f e e l . Some foamers reproduce t h i s by adhering two grades o f foam i n t o one item. A t h i r d type o f c o n s t r u c t i o n uses woven f a b r i c s or s o l i d foams as b a r r i e r s to reduce open flame combustion o f f u r n i t u r e and mattresses used i n the commercial or i n s t i t u t i o n a l markets ( F i g u r e k). The mattress market h i s t o r y p r o v i d e s an i n t e r e s t i n g view o f one i n d u s t r y ' s response to the f o r c e d i n t r o d u c t i o n o f a flammab i l i t y standard. The message o f a d a p t a t i o n , r a t h e r than comp l e t e change, i s perhaps a preview o f the f u t u r e f o r the furniture industry. Whatever the combination o f f a b r i c and construction, industry recognizes the importance o f these v a r i a b l e s i n the o v e r a l l assessment o f f i r e r i s k and has adapted manufacturing to reduce f i r e hazards. Future T e s t i n g , Standards and I n d u s t r y A c t i o n F i r e codes or standards have governed urethane business f o r some time and have played a prominent r o l e i n the c r e a t i o n o f b u i l d i n g codes. Unfortunately, f i r e s t a t i s t i c s currently are based on a minimum number o f c o l l e c t e d f i r e cases which become the base f o r r e g u l a t o r y a c t i v i t y that impacts i n d u s t r y and consumers. At f i r s t , p r o p e r t y p r o t e c t i o n was the key concern to those studying f i r e hazards. However, during the past decade an emphas i s s h i f t has refocused a t t e n t i o n to the n o n - s t r u c t u r a l and personal l i f e s a f e t y parameters o f f i r e . Many t e c h n i c a l codes and standards r e f l e c t t h i s s i g n i f i c a n t progress o f the past decade ( F i g u r e 5)· T h i s c h a r t i n 1 9 8 9 would show f u r t h e r changes i n f u t u r e f l a m m a b i l i t y standards. An a n a l y s i s o f the impact o f some o f the c u r r e n t standards r e f l e c t s a trend which may continue through the ' 8 0 s . For i n s t a n c e , the f e d e r a l c i g a r e t t e i g n i t i o n standard imposed on the mattress i n d u s t r y i n 1 9 7 3 r e s u l t e d i n l i t t l e change i n the penet r a t i o n o f f u l l foam mattresses i n t o a dominantly i n n e r s p r i n g


Urethane Foam


SCHUHMANN

Change in bed-related fire/burn fatalities, 1974-1978

-28%

Change in number of fire/burn fatalities in private dwellings, 1974-1978

+17%

Change in number of fire/burn fatalities, 1974-1978

-13%

Source: Consumer Product Safety Commission Report dated 1980.

Figure 3.

Effectiveness of FF4-72 federal cigarette mattress standard (enforce December 1973).

Conventional A

Engineered Β

ο ο ο

ο ο ο

ο ο ο

ο ο ο ο ο ο ο ο

ο ο ο

ο ο ο

Foam

ο ο ο

Class I Fabric

ο ο ο ο ο ο ο ο

_ο_ ο _ O__Q^_£>OOCL

Interliner

o o o o o o o o o o o o o o o o Ο

Ο Ρ Ο

Figure 4.

Figure 5.

O O P

UFAC Fiberfill Barrier Class 11 Fabric

ο

Class 11 Fabric

Construction options.

Flammability standards.



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economy. I t d i d , however, r e s u l t i n a q u i l t replacement and a 50% s w i t c h to urethane foam toppers. I n n e r s p r i n g s , however, remain unchallenged i n the r e s i d e n t i a l bedding market. By c o n t r a s t i n s t i t u t i o n a l and p r i s o n mattress markets have s p e c i a l needs best met by a urethane core type mattress. These i n c l u d e the need f o r repeated s a n i t i z i n g and reduced handling weight. I n p r i s o n s , mattresses must be designed to c o n t r o l h i d den contraband as w e l l . While t h i s market volume i s only f i v e m i l l i o n pounds per year, i t demands open-flame r e s i s t a n t foam. I t i s a very v i s i b l e market and r e g u l a t i o n s developed f o r t h i s market w i l l p o t e n t i a l l y impact the r e s i d e n t i a l s e c t o r . As we enter the '80s, s e v e r a l f u t u r e f l a m m a b i l i t y standards are i n i n i t i a l stages o f development. Industry has been cons i d e r i n g more s t r i c t performance standards f o r r e s i d e n t i a l use, some s p e c i a l i s t s b e l i e v e a l l foam components should pass Cal. 117 v e r t i c a l open flame t e s t i n g requirements. Others, i n c l u d i n g CPSC and UFAC r e p r e s e n t a t i v e s , b e l i e v e f i n a l composit i o n performance must be the bottom l i n e i n s e t t i n g standards. However, long-term composite t e s t i n g and open-flame t e s t i n g w i l l be s t r e s s e d i n the i n d u s t r y . F i r e growth r a t e s w i l l be the b a s i s f o r performance standards i n the i n s t i t u t i o n and commerc i a l applications. There w i l l be two p a r a l l e l t h r u s t s based on composite and component s o l u t i o n s . The composite t h r u s t w i l l be the i n i t i a l area o f concentrated t e s t s and standards. This emphasis w i l l be succeeded by a s e r i e s o f component or product r e l a t e d s o l u t i o n s l i k e the UFAC l a b e l i n g and i n t e r l i n e r approaches (Figure 6 ) . Though the standards a t d e s t i n a t i o n I have been e s t a b l i s h e d f o r component foam t e s t i n g , they w i l l become secondary to the n a t i o n a l i n d u s t r y v o l u n t a r y c o n t r o l s as o u t l i n e d i n the UFAC program. In the next two steps the r e s i d e n t i a l upholstered f u r n i t u r e questions should be r e s o l v e d . The second d e s t i n a t i o n i s an a p p r o p r i a t e open flame composite assessment t e s t along w i t h an improved UFAC c i g a r e t t e r e s i s t a n c e t e s t . The t h i r d d e s t i n a t i o n w i l l be development o f a foam that meets UFAC l a b e l i n g t e s t requirements and r e p l a c e s t h e i r c o n s t r u c t i o n approach. F i n a l l y , urethane foams w i l l have a f l a m m a b i l i t y p e r f o r mance p e r m i t t i n g t h e i r general use i n n o n - r e s i d e n t i a l occupancies. These would i n c l u d e high r i s k mattress and l a t e r f u r n i t u r e uses. Some d i f f i c u l t y has a r i s e n i n determining appropriate t e s t s for s e t t i n g these standards. C i g a r e t t e smoldering ignition t e s t s a r e p r e d i c t a b l e because the i g n i t i o n sequence can be reasonably defined. Fine tuning i s needed, but f i r e experts a r e r e l a x e d w i t h today's c i g a r e t t e i g n i t i o n t e s t i n g as b a s i c a l l y realistic. By c o n t r a s t , the p o s s i b l e i g n i t i o n scenarios are so broad for open o r d i f f u s e d flame, f i r e s , that many d i f f e r e n t t e s t s have been d e r i v e d . Though each o f these t e s t s has m e r i t , no



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s i n g l e method has gained u n i v e r s a l acceptance. Consequently, an e s t a b l i s h e d B r i t i s h f u r n i t u r e standard has been recognized f o r i t s v a r i e d i g n i t i o n source r e s i s t a n c e and i s the proposed European Common Market standard. This concept was used i n the p r i s o n mattress program a t the C a l i f o r n i a Bureau o f Home F u r n i s h i n g s and the Metro Bus P r o j e c t a t the N a t i o n a l Bureau o f Standards. In summary, reducing f i r e hazard — not passing t e s t s — i s our i n d u s t r y ' s g o a l . We must be a l e r t to the s t a t u s and changes i n our n a t i o n ' s f i r e experience. We a r e doing t h i s cooperat i v e l y through i n d u s t r y groups l i k e the Urethane D i v i s i o n o f SPI. Business Impact The e r a o f composite s o l u t i o n s w i l l be 1980-83 (Figure 7 ) · Changes w i l l occur i n foam use but no dramatic change i n present urethane foam f i r e property mix i s expected during t h i s p e r i o d . In s e t t i n g standards f o r the i n d u s t r y , UFAC s v o l u n t a r y program w i l l g a i n n a t i o n a l prominence. The C a l i f o r n i a standard w i l l change i n importance from foam c o n t r o l to become the c a t a l y s t f o r f a b r i c improvement. UFAC ' s l a b e l i n g program does not c a l l f o r a unique f i r e performing foam unless UFAC q u a l i t y i s a v a i l a b l e . That q u a l i t y w i l l not be commercially achieved during t h i s three-year p e r i o d , thus we do not look f o r a s i g n i f i c a n t s h i f t i n the f i r e performance mix o f the urethane foam s o l d . During t h i s p e r i o d , use o f c e l l u l o s i c u p h o l s t e r y f a b r i c s c o u l d be reduced to a 50% market share to r e t a i n as much e n g i neered c o n s t r u c t i o n as p o s s i b l e . I n accordance w i t h UFAC c r i t e r i a , c o n s t r u c t i o n w i l l be employed to meet UFAC standards. However, there may be a higher value placed on urethane foams for use w i t h s y n t h e t i c u p h o l s t e r y f a b r i c s . Commercial and i n s t i t u t i o n a l markets w i l l choose "C" type c o n s t r u c t i o n s o r s p e c i a l i z e d combustion r e s i s t a n t foam but market impact w i l l be minor. The e r a o f component s o l u t i o n s f o r the r e s i d e n t i a l f i r e problem should begin about 1984. I n the f u r n i t u r e market both foam and f a b r i c w i l l meet UFAC requirements i n order to pass smoldering t e s t s . During t h i s stage a dramatic change should take p l a c e i n the f i r e performance property mix o f foams s o l d i n t o the f u r n i t u r e i n d u s t r y . C r e a t i v e technology w i l l achieve cost e f f e c t i v e foams t h a t c o n t r o l smoldering and demonstrate open flame r e s i s t a n c e as defined by C a l . 117· The upholstered furniture industry w i l l then r e v e r t back t o c o n v e n t i o n a l c o n s t r u c t i o n s and pay a premium p r i c e f o r foam. Concurrently the f a b r i c i n d u s t r y w i l l announce a s i m i l a r achievement f o r c e l l u l o s i c u p h o l s t e r y f a b r i c s . These w i l l be t r e a t e d f o r a c l a s s "A" r a t i n g without property p e n a l t y . While the c l a s s "A" heavyweight c o t t o n u p h o l s t e r y f a b r i c represents a


110

URETHANE


1985

CHEMISTRY A N D

APPLICATIONS

IV. HIGH RISK FURNITURE AND BEDDING STANDARD

1984 High Risk Performance Standard 1983

1982

1981

III.

UFAC FURNITURE SMOLDERING RESISTANCE STANDARD

High Risk Construction Criteria II. SMALL OPEN FLAME COMPOSITE TEST; REFINE UFAC CIGARETTE TEST I. CAL. 117 SMOLDERING/OPEN FLAME COMPONENT TEST High Risk Test Concept

1980

UFAC Construction Criteria

1979 PRODUCT APPROACH Figure 6.

Composite Approach

Flammability standards and action during the 1980's.

"I J

Engineered Construction

II

Late 70's Figure 7.

Early 80's

Mid 80's +

Market changes due to flammability concern: residential upholstere furniture.



9.

SCHUHMANN

Urethane Foam

111

UFAC smoldering s o l u t i o n , i t a l s o i s the most p r a c t i c a l openflame i g n i t i o n s o l u t i o n f o r the upholstered f u r n i t u r e market. By 1 9 8 6 , the impact on urethane foam w i l l be a conversion to about k0% UFAC grade foam f o r the f u r n i t u r e i n d u s t r y . An estimated 10% o f the u p h o l s t e r y f a b r i c s w i l l be c o t t o n . Sixty percent o f that w i l l be UFAC "A" grade. I n d i v i d u a l l y , f u r n i t u r e manufacturers w i l l choose e i t h e r or both s o l u t i o n s but i t w i l l be common to r e v e r t back to conventional c o n s t r u c t i o n . Not only w i l l an i n d i v i d u a l product r i s k performance be questioned, but i t s r o l e i n the o v e r a l l environment w i l l be brought i n t o focus. This e r a o f the l a t e ' 8 0 s , t h e r e f o r e , may be c a l l e d the e r a o f environmental o r system s o l u t i o n s as d i f f e r e n t i a t e d from component o r composite s o l u t i o n s . We have an opportunity to shape and mold the f u t u r e , and to b e n e f i t s o c i e t y by our s t r u g g l e w i t h assessing f i r e hazard. I t i s a challenge the urethane i n d u s t r y has already begun to meet. Summary T h i s paper recognizes the presence o f a f i r e - r i s k i n many products, as w e l l as components. F i r e r i s k was described by s t a t i s t i c s f o r products that c o n t a i n urethane foams. Those products can be r e l a t e d to f i r e f a t a l i t i e s , i g n i t i o n source, o r occupancy f a c t o r s . The f e d e r a l data c o l l e c t e d about frequency and consequences o f our nation's f i r e l o s s e s cannot t e l l us which, o r how many, o f these products d i d c o n t a i n urethane foam. Our a v a i l a b l e data i n that area cannot give a persuasive d e s c r i p t i o n o f the s i t u a t i o n . The paper presents evidence to show that the urethane i s o cyanate i n d u s t r y i s doing something to minimize f i r e r i s k assoc i a t e d w i t h i t s m a t e r i a l s . The framework o f codes and standards now i n place should l e a d to a future r e d u c t i o n o f f i r e l o s s e s . S t i l l , we are not sure we have f u l l y resolved the question o f "how t o " assess f i r e r i s k . But, as an i n d u s t r y we are working on that and our route i s i n p l a c e . For the urethane i n d u s t r y , the immediate future w i l l be a f f e c t e d only by a s l i g h t decrease i n the volume o f foam used by the f u r n i t u r e i n d u s t r y w i t h no change i n present combustion performance mix. T h i s i s the r e s u l t o f the f u r n i t u r e i n d u s t r y ' s option f o r c o n s t r u c t i o n a d a p t a t i o n , r a t h e r than component change. Component s o l u t i o n s i n foam and f a b r i c w i l l c h a r a c t e r i z e 1983 to I986. Foam w i l l r e c l a i m i t s market p o s i t i o n and a s i g n i f i c a n t p o r t i o n o f foam s o l d w i l l be h i g h l y r e s i s t a n t to smoldering. F o r t u i t o u s l y , the best open flame s o l u t i o n w i l l be a by-product o f t h i s a c t i v i t y . The l a t e '80s w i l l f i n d the urethane market a f f e c t e d by the rougher problems o f managing more severe open-flame f i r e s i t u a tions. The i n s t i t u t i o n a l market s i z e i n v o l v e d w i l l be s m a l l , but w i l l have a s u b t l e e f f e c t on the r e s i d e n t i a l market f o r urethane foams. Edwards et al.; Urethane Chemistry and Applications ACS Symposium Series; American Chemical Society: Washington, DC, 1981.

112


APPLICATIONS

We must communicate to a l l users o f urethane foam accurate f i r e r i s k i n f o r m a t i o n . S P I s b u l l e t i n , "Using F l e x i b l e Urethane Foams S a f e l y " and other s a f e t y documents are v a l u a b l e only as they are read and understood. This i s a c r i t i c a l task. Foam w i l l burn. Though we make i t more i g n i t i o n r e s i s t a n t or slower i n f i r e growth, the r e a l t e s t i s i n the f i n i s h e d product s performance. Today's urethane foam f i n i s h e d products are improving our q u a l i t y o f l i f e and w i l l have an even more p o s i t i v e impact on reducing f i r e hazard i n the f u t u r e .


1

1

RECEIVED April 30,

1981.


Urethane Chemistry and Applications - ACS Publications - American

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