Fire” from Rosenheim – High-Tech Fire Resistance Test in the Service of Security Page 1 of 7

Publication – ift Rosenheim

Prof. Ulrich Sieberath, Dr. Gerhard Wackerbauer, Anyke Aguirre Cano The “Fire” from Rosenheim – High-tech Fire Resistance Test in the Service of Security Page 1 of 7

Prof. Ulrich Sieberath – Director of Institute ift Rosenheim Dr. Gerhard Wackerbauer – Head of Notified Product Certification Body Fire Safety Dipl.-Ing. (FH) Anyke Aguirre Cano – Head of Testing Body Fire Safety

The “Fire” from Rosenheim High-tech Fire Resistance Test in the Service of Security

No, we do not forge “magic rings” for elves in the “fire” of ift Rosenheim. Furthermore, 20 burner with a performance of each 600 kWh spark of a “standard fire” with up to 1,200 °C, which complies exactly with the temperature-time curve according to EN 1363-1. The fire resistance of doors, gates, walls, glazings and other bulding elements can be tested in order to ensure the resistance in case of a fire for 90 minutes and more. If the fire safety elements fail in case of emergency and people will be injured, usually the judiciary springs into action to investigate the causes. Then, everything is turned upside down and it will be investigated if the used fire safety elements were working, the necessary test certificates are available and if they comply with the regulations. Therefore, ift Rosenheim has invested a lot and built a furnace with 8 m width and 5 m height in the new ift technology center. In Juli 2017, another furnace with the dimensions 5 m x 5 m will be moved to Rosenheim from the ift Centre for Fire Testing in Nuremberg. For many years now, the competent ift fire protection team led by Dr. Gerhard Wackerbauer and Anyke Aguirre Cano tests the fire resistance and the fire behaviour of building elements and building materials. Above all, the exact control of the fire resistance test according to normative specifications with corresponding tolerances is important. The following publication shows how this is made.

Image 1 The “test fire” in the furnace with 8 m x 5 m of the ift technology center is not to “forge rings” for elves but guarantees reproducible, reliable and standard-compliant tests that can be used worldwide as proof of fire resistance.

Prof. Ulrich Sieberath, Dr. Gerhard Wackerbauer, Anyke Aguirre Cano The “Fire” from Rosenheim – High-tech Fire Resistance Test in the Service of Security Page 2 of 7

1 Large and still burning according to standard – is this also possible with large furnaces?

For a long time, the fire resistance tests could only be made in “small” furnaces with an opening of 3 m x 3 m. At the same time, building components in fire protection are getting larger, so that the testing bodies had to extrapolate the tests. However, practice shows that reliable statements for fire resistance could only be given when testing large test elements. So even larger furnaces were built that have demonstrated the deficiencies and limits of some extrapolation rule. Therefore, a close eye on and in the furnaces is interesting in order to understand how a “standard fire” is controlled and the complete building element is exposed to the normative defined loads. Besides, there are rather generous tolerances for the furnace. The temperature distribution can deviate by ± 100 °C from the determined temperature value (generally the standard temperature-time curve). If one considers that with an excess of 1 °C of the limit of the temperature on the surface of the test specimen the reached class is already influenced, it becomes apparent that an even temperature distribution in the furnace is essential.

Image 2 The standard temperature-time curve (ETK) of the ift furnace 8 m x 5 m. The diagram shows that the normative limit of the EN 1363-1 is optimally fulfilled and the force applied on the test specimen ideally complies with the standard specifications.

Prof. Ulrich Sieberath, Dr. Gerhard Wackerbauer, Anyke Aguirre Cano The “Fire” from Rosenheim – High-tech Fire Resistance Test in the Service of Security Page 3 of 7

2 Temperature distribution

If you monitor fire resistance tests at thermal insulated glasses closely, you will realize that the intumescence of the insulating layers starts in small areas and then spreads very quickly. As the reaction of the intumescent material starts at a certain temperature, the spatial and temporal temperature distribution in the furnace can easily be observed. The burner for the generation of the temperature in the furnace are generally arrange at the sides with flames parallel to the surface. The exhaust gases are mostly be extracted centrally via some openings in the centre of the back of the furnace. This will result in a higher temperature in the center of the furnace. In order to load the test specimen evenly, the furnaces can be built so large that the cooler areas are located outside of the test opening. At ift Rosenheim, the “old” furnace with 3 m x 3 m was designed according to this principle, i.e. the test opening was 3 m and the chamber was 4 m wide. In addition, there are six exhaust ports instead of one, so that a even loading of the test specimen with the temperature-time curve was achieved. This principle was transferred to the large wall test furnace in the new ift technology center. The furnace has a maximum size of 8 m width and a height of 5 m, which can be completely used for the tests. The exhaust gases are exhausted via a variable number of openings, so that an ideal and very homogeneous temperature distribution arises during tests at a size of 5 m x 5 m.

Image 3 The evenly spread intumescence of the layers of a fire resistant glazing presents the temperature distribution at the test specimen and is a good indicator for the quality of the furnace.

Prof. Ulrich Sieberath, Dr. Gerhard Wackerbauer, Anyke Aguirre Cano The “Fire” from Rosenheim – High-tech Fire Resistance Test in the Service of Security Page 4 of 7

What happens with tests of XXL building elements that needs the complete furnace size of 8 m width? For optimal test conditions, the known problem of the clear temperature drop at the edges and the higher temperatures in the centre has to be avoided. Therefore, the engineers at ift Rosenheim developed innovative solutions with the furnace manufacturer of ift MessTec (a subsidiary of ift Rosenheim). When using the complete furnace opening of 8 m width and 5 m height, an ideal, even temperature distribution is created by installing “temperature distributer” in the furnace chamber, so that neither the edges are underloaded nor the centre is overloaded and therefore preventing the risk of premature failure of the test specimen by stress cracks. Hence, a furnace with excellent temperature and pressure distribution is available for manufacturer of fire resistant building components. The furnace maintains the normative permitted tolerances optimally and that with the sizes 5 m x 5 m and 8 m x 5 m.

3 Oil or Gas – no question of technology!

As long as there are fire resistance tests, the correct fuel will be discussed. Wood was used as fuel in old DIN standards, which was replaced by oil. Since the introduction of the European fire classification standards gas may also be used. To start with - the temperature is high with all fuels. While older oil burner were hard to control as they could only be used in “on” or “off” mode, the modern oil burner in the technology center can be controlled “sensitively” like gas burner. In addition, the yellow lighting “torches” of old oil burner and the related excessive air heating, thermal radiation and soot formation are things of the past. The flames of modern oil burner are compact and the exhaust gases as hot as the exhaust gases of gas burner. The furnace chamber will be heated that the heat reaches the test specimen as thermal radiation, so that there are no differences to gas burner during loading. However, the violent pressure shock which occurred while ignitition of the oil burner and damaged the test specimen is not present in this form in modern burner.

Prof. Ulrich Sieberath, Dr. Gerhard Wackerbauer, Anyke Aguirre Cano The “Fire” from Rosenheim – High-tech Fire Resistance Test in the Service of Security Page 5 of 7

4 Pressure distribution

The pressure distribution in the furnace affects the distribution of hot gases that takes a significant amount of heat in the joints of the test specimen due to leaks. Therefore, the pressure distribution is also part of the verification of the furnace according to EN V 1363- 3. Considering the large amounts of fuel and the accompanying combustion air and exhaust gases, it is astonishing that an even pressure gradient is set. This is only possible if the adjustment between furnace size and exhaust ports is right. Therefore, years of experience and competence in construction and operation of furnaces are necessary, of which the experts at ift Rosenheim, ift MessTec and Peiner Ofenbau have, so that the approval and calibration of the new furnace in the technology center was passed withouth any problems. The normative necessary pressure value was reached earlier than requested (see image 3, dashed line), already after 1-2 minutes, and stuck to it with high precision for the remaining time of the test. Also with pressure-sensitive fire curtains, a standard deviation of only σ = 1 Pa was reached. For comparison: The wind force 1 (“light air”) correspond after Beaufort 10 Pa, wind force 3 (“gentle breeze”) is already 70 – 180 Pa.

Image 4 Pressure pattern at fire resistance test with a specification of 20 Pa. The diagram shows that the normative limit is optimally fulfilled and the force applied on the test specimen is reduced to a minimum.

Prof. Ulrich Sieberath, Dr. Gerhard Wackerbauer, Anyke Aguirre Cano The “Fire” from Rosenheim – High-tech Fire Resistance Test in the Service of Security Page 6 of 7

5 Conclusion

At the ift technology center, both furnaces (8 x 5 m and 5 x 5 m) with the latest burner and exhaust technology guarantee the manufacturer of fire resistant components standard- compliant, reliable and reproducible test conditions. The service includes also rapid and prompt processing of the test order and the expert advice of clients by the experienced ift- experts in Nuremberg and Rosenheim. In Nuremberg, the experts of the “notified product certification body” plan and coordinate the test specimen and the tests according to the motto “as many tests as necessary and as little as possible”. In 2018, further furnaces will be added in Rosenheim in order to offer manufacturer the most efficient test combinations.

Image 5 The ift technology center enables rapid and efficient fire tests of large-size components up to 8 m x 5 m for national and international necessary evidences according to EN, UL and further standards.

Prof. Ulrich Sieberath, Dr. Gerhard Wackerbauer, Anyke Aguirre Cano The “Fire” from Rosenheim – High-tech Fire Resistance Test in the Service of Security Page 7 of 7

Literature

[1] EN 1363-1 – Fire resistance tests - Part 1: General requirements [2] V ENV 1363-3 – Fire resistance tests - Part 3: Verification of furnace performance [3] EN 16034 – Pedestrian doorsets, industrial, commercial, garage doors and openable windows - Product standard, performance characteristics – Fire resistance and/or smoke control characteristics [4] EN 1634-1 – Fire resistance and smoke control tests for door and shutter assemblies, openable windows and elements of building hardware - Part 1: Fire resistance test for door and shutter assemblies and openable windows

Standards and excerpts from the standard are published with the knowledge of DIN Deutsches Institut für Normnung e.V. (German Institute for Standardization). The version with the most resent issue date is relevant for the use of DIN standards, which can be bought at Beuth Verlag GmbH, Burggrafenstr. 6, 10787 Berlin, Germany.

Authors: Professor Ulrich Sieberath is the head of ift Rosenheim and working for more than 30 years in the window, facade and glass industry. He provides his extensive experience and expertise nationally and internationally in many technical committees and specialized bodies as well as assessor, subject specialist, author and lecturer.

Dr. Dipl.-Phys. Gerhard Wackerbauer is head of the Notified Product Certification Body Fire Safety at ift Rosenheim. For many years, he was working as physicist in the area sound insulation, humidity and thermal insulation and represents the ift in various standards committees as well as speaker and author.

Dipl.-Ing. (FH) Anyke Aguirre Cano is working as head of testing body for fire safety and resistance to fire for ift Rosenheim.

About ift Rosenheim ift Rosenheim is an European notified testing, surveillance and certification body that is internationally accredit- ed according to DIN EN ISO/IEC 17025. Its focus is on the practice-oriented, holistic and rapid testing and classification of all characteristics of windows, facades, doors, gates, glass and building materials. It aims to bring about sustained improvements in product quality, design and technology, and in standardisation and re- search. Certification by the ift Rosenheim ensures acceptance throughout Europe. The ift also sees the dis- semination of knowledge as an obligatory part of its work. As an independent institute, the ift enjoys a special status among the media, and its publications document the current state of the art.