FireGuard | Every second counts: Fire safety in cleanrooms (part 1)

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FireGuard | Every second counts: Fire safety in cleanrooms (part 1)

Grenfell Tower's Tragedy: A Catalyst for Emphasizing Fire-Resistant Materials

The fire at Grenfell Tower on June 14, 2017, in North Kensington, London, underscored the critical importance of fire-resistant materials in building construction. This incident, which led to 72 fatalities and numerous injuries, was aggravated by the building’s flammable cladding, prompting a global reassessment of safety regulations and construction materials.

In response, prioritizing fire safety, particularly in specialized environments such as cleanrooms, has become essential. ABN Cleanroom Technology addresses this imperative with the introduction of FireGuard, an integral building block of our Adaptus product platform. FireGuard is not just about enhancing the fire resistance of cleanrooms; it represents a comprehensive methodology that incorporates pre-engineered processes such as risk analysis, passive fire safety strategies, and active fire safety systems, ensuring a holistic approach to safety and compliance in these highly controlled environments.

Adaptus, developed by ABN Cleanroom Technology, is a versatile product platform that integrates both physical and conceptual products, streamlining the creation, maintenance, and monitoring of cleanroom environments. This platform is designed to deliver comprehensive cleanroom management solutions, with FireGuard serving as a key component in achieving superior fire safety and regulatory compliance.FireGuard is a vital component and building block of the Adaptus platform, focused on significantly improving the fire safety of cleanrooms. This whitepaper will introduce FireGuard, emphasizing two of its key components: Reaction to Fire and Fire Resistance , which are crucial for enhancing cleanroom fire safety.

Reaction to fire

Reaction to Fire assesses how materials behave and contribute to the progression and spread of a fire. Controlling the reaction of materials to fire is essential to prevent rapid fire spread, which can have catastrophic consequences. Fireguard materials are specifically engineered to minimize their combustibility and flame spread characteristics, ensuring cleanrooms remain safe and compliant with fire safety standards.

FM-Approved panels & ceiling

Fire Resistance measures a material’s ability to withstand fire without compromising its structural integrity. This is critical for maintaining fire containment, allowing sufficient time for evacuation and intervention by fire services. Fireguard materials undergo rigorous testing and certification to meet the highest standards of fire resistance. This includes the use of fire-resistant coatings and structural materials capable of withstanding high temperatures for extended periods.

By incorporating FireGuard into the Adaptus platform, ABN Cleanroom Technology is committed to setting new benchmarks in fire safety for cleanroom environments. This whitepaper explores the specifics of FireGuard, detailing how it addresses fire safety challenges and aligns with our mission to provide the safest and most reliable cleanroom solutions.

Reaction to fire

EN 13501-1: The European Standard for Fire Classification

Since March 1, 2003, Europe has adopted the EN 13501-1 standard, which uses the ISO 9705 Room Corner test to classify materials based on their fire performance. This standard plays a vital role in fire safety by helping designers choose materials that meet the required safety standards, ensuring compliance with EU regulations, mitigating risks related to fire spread, smoke development, and hazardous burning droplets, and ultimately protecting building occupants.

Classification System

The EN 13501-1 standard categorizes materials into a detailed classification system with three main components:

Main Class: This includes classifications from A1 to F, where A1 and A2 represent non-combustible materials with A1 materials contributing nothing to fire and A2 materials contributing very little. Class B materials contribute very little to a developing fire, while Class C materials contribute moderately. Classes D and E represent materials that contribute significantly and highly to fire development, respectively. Class F has no specified performance requirements.
Smoke Production: This component is categorized into s1, s2, and s3, indicating low, average, and high smoke production, respectively.
Droplet Formation: Classified as d0, d1, and d2, this indicates the amount of burning droplets or particles produced, with d0 producing none, d1 producing a limited amount, and d2 producing a free amount.

Fire Safety in Cleanrooms

For cleanrooms, it’s essential to use materials that comply with high fire safety standards. ABN Cleanroom Technology ensures that the cleanrooms they design and build meet the following criteria:

Preferred main class of A1/A2, at minimum B
Preferred smoke production of s1
Preferred droplet formation of d0

By adhering to these stringent fire safety classifications, ABN Cleanroom Technology ensures their cleanrooms provide superior protection against fire risks, maintaining a safe environment for both personnel and sensitive operations.

FM-Approved panels & ceiling

The FM Approved label is a mark of quality, safety, and performance awarded by FM Global, a leading insurance company specializing in property insurance and risk management. Products, services, or installations bearing the FM Approved label have undergone rigorous testing and inspection to meet stringent criteria established by FM Global, particularly in the realm of fire safety. FM Global is renowned for its stringent test procedures and standards, making the FM Approved label a trusted mark of excellence in safety.

FM 4882: Class 1 Interior Wall and Ceiling Materials for Smoke-Sensitive Occupancies

The FM 4882 standard is critical for materials used in cleanrooms and other process-critical environments. Compliance with this standard ensures that facilities offer the highest levels of fire safety and smoke control, which is essential for protecting personnel, equipment, and processes. Low-smoke wall and ceiling panels certified to meet FM 4882 requirements limit fire propagation and generate significantly less smoke than traditional panels.

FM 4882 applies to interior wall and ceiling materials or systems used in cleanrooms, pharmaceutical manufacturing, and storage areas. Materials or systems categorized for use in cleanrooms must meet the requirements of the Test Standard for FM Approvals Cleanroom Materials Flammability Test Protocol (Class Number 4910) and the American National Standard for Cleanroom Materials Flammability Test Protocol (ANSI/FM Approvals 4910) in addition to other requirements of this standard.

Sandwich Panels or Composite Panels

The use of sandwich panels in cleanroom construction has increased significantly over the last two decades. These composite panels are effective for achieving high levels of energy efficiency while allowing for flexible and aesthetically pleasing design. They come with various types of insulation materials, metal finishes, and colors, some of which include additional fire-retardant materials.

However, there have been significant fire losses involving combustible composite panels, particularly in the pharmaceutical and electronic industries. Composite panels consist of two coils of facing material (either aluminum or metal) that are approximately 1.1 meters wide. These come together after being cleaned and dried to a preset depth/thickness, at which point insulation is added.

Given the varying composition of the insulation material, it is crucial to understand the different types of insulation that can be used:

Polystyrene Expanded and Extruded: Polystyrene is a thermoplastic rigid cellular material known as expanded (EPS) or extruded (XPS) polystyrene foam. It melts and ignites easily, rapidly burns, and produces thick toxic smoke, making firefighting extremely difficult. Polystyrene panels are not recommended for modern cleanroom design and do not receive the FM Approved label.
Polyurethane: Polyurethane (PUR) is a thermoset plastic that initially chars in a fire but will ignite and burn when exposed to prolonged intense heat. It contributes significantly to the fire load and creates thick toxic smoke, making firefighting challenging. PUR panels do not receive the FM Approved label due to their poor fire properties.
Polyisocyanurate: Polyisocyanurate (PIR) is similar to polyurethane but performs better in fire situations when a 10% fire retardant solution is added during the manufacturing process. While PIR still contributes to the fire load, panels from certain manufacturers can receive the FM Approved label.
Mineral Fibre/Glass Wool: Mineral fibre/glass wool insulation is non-combustible and widely used in cleanroom construction. Due to its excellent fire properties, many manufacturers have achieved the FM Approved label for this type of insulation.
Aluminum Honeycomb: Aluminum honeycomb insulation offers excellent sustainability characteristics, such as circularity, making it well-suited as an insulation medium. This high-end panel typically features an FM Approved label due to its superior fire safety properties.

By using FM-approved panels, ABN Cleanroom Technology ensures that their cleanrooms meet the highest standards of fire safety, providing a secure environment for sensitive operations and personnel.

Conclusion

Maintaining the highest levels of fire safety and smoke control in cleanrooms is essential. The use of FM 4882 certified materials is instrumental in achieving this by ensuring the following:

Safety of Personnel: Minimizing smoke production and toxicity ensures that personnel can evacuate safely without being exposed to harmful smoke.
Protection of Equipment and Processes: Smoke-free environments are crucial for protecting sensitive equipment and processes that could be adversely affected by smoke and contaminants.
Compliance with Regulations: Using FM 4882 certified materials helps cleanrooms comply with the strictest fire safety standards and regulations.
Risk Management: By adhering to the FM 4882 standard, companies can significantly reduce the risk of fire and smoke damage, leading to a safer and more reliable operational environment.

Through the incorporation of fire-resistant materials, the robust management capabilities of Adaptus, and the enhanced fire safety features of FireGuard, ABN Cleanroom Technology demonstrates its commitment to providing safe, reliable, and compliant cleanroom solutions. This proactive approach ensures that cleanroom environments not only meet but exceed the necessary safety requirements, safeguarding both personnel and critical operations.

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