NFPA 285: Assembly Test of Exterior Walls with Combustible Components

AIA/CES LU Learning Objectives Understand the Impact of the NFPA 285 Test in Relation to the International Building Code Apply the NFPA 285 Assembly Test Components and Parameters to Successful Test Performance Identify Combustible Components in a Noncombustible Wall Assembly that Trigger NFPA 285 Testing Design Building Envelope Systems as Part of NFPA 285 Compliant Assembly Variations

Section 1: Impact of the NFPA 285 Test and the International Building Code (IBC)

Construction Types (IBC ch 5, 6) SECTION 1 Construction Types (IBC ch 5, 6) Type V Combustible Construction Type IV Heavy Timber Construction Type III Non-Combustible Exterior Type II Non-Combustible Exterior and Components Type I Non-Combustible Materials and Structure Combustible Non-Combustible 602.2 Types I and II. Type I and II construction are those types of construction in which the building elements listed in Table 601 are of noncombustible materials, except as permitted in Section 603 and elsewhere in this code. 602.3 Type III. Type III construction is that type of construction in which the exterior walls are of noncombustible materials and the interior building elements are of any material permitted by this code. Fire-retardant-treated wood framing complying with Section 2303.2 shall be permitted within exterior wall assemblies of a 2-hour rating or less. 602.4 Type IV. Type IV construction (Heavy Timber, HT) is that type of construction in which the exterior walls are of noncombustible materials and the interior building elements are of solid or laminated wood without concealed spaces. The details of Type IV construction shall comply with the provisions of this section. Fire-retardant-treated wood framing complying with Section 2303.2 shall be permitted within exterior wall assemblies with a 2-hour rating or less. Minimum solid sawn nominal dimensions are required for structures built using Type IV construction (HT). For glued-laminated members the equivalent net finished width and depths corresponding to the minimum nominal width and depths of solid sawn lumber are required as specified in Table 602.4. 602.5 Type V. Type V construction is that type of construction in which the structural elements, exterior walls and interior walls are of any materials permitted by this code. - Each Type has an “A” and a “B” sub-category - “A” has increased fire protection requirements

Construction Types Examples SECTION 1 Construction Types Examples Fitzgerald's Heavy Timber Construction, Inc., 2006 http://desource.uvu.edu/ctc/iaco/iaco_01.php Mark Martin @ http://www.houstonrealestateobserver.com Type V Type IV Type III Type I Type II Combustible Non-Combustible Wikimedia Commons, © Daniel Schwen Firefightersenemy.com, dc802

Maximum Building Height (IBC Table 503) SECTION 1 Maximum Building Height (IBC Table 503) Including 1-story sprinkler system increase Chart shows height, baseline Allowable area also increases from Type V-Type I. For example: Education Type V (2/SF), Type III (4/SF), Type II (4/SF) SF has many additional multipliers: lot separation distance, sprinklers, frontage, Source: 2012 International Building Code

IBC Fire Related Tests and Reports SECTION 1 IBC Fire Related Tests and Reports Product Properties ASTM E84 Surface Burning Characteristics ASTM E1354 Cone Calorimeter Test ICC ES Reports (compliance aid, not a test method) Assembly Properties ASTM E 119 or UL 263 Fire Rated Walls NFPA 268 Radiant Ignitibility of Assemblies NFPA 285 Walls With Combustible Components ASTM E84: Surface Burning Characteristics -Comparative measurements of product surface flame spread and smoke density -Does NOT: Measure heat transmission, Determine assembly flame spread behavior, or Classify material as noncombustible Class Flame Spread Index Smoke Developed Index A 0-25 0-450 B 26-75 0-450 C 76-200 0-450 ASTM E1354 – Cone Calorimeter Test -Heat of combustion, mass loss rate, time to sustained flaming, and smoke production -Small sample specimen -Applies to various categories of products -Is not limited to representing a single fire scenario ICC ES Reports -Agencies use evaluation reports to help determine code compliance and enforce building regulations -Manufacturers use reports as evidence that their products meet code requirements and warrant regulatory approval. -This is especially important if the products are new and innovative ASTM E 119 or UL 263 (IBC 703.2) Fire Rated Walls UL rated assemblies NFPA 268: Radiant Ignitibility of Assemblies -Tests for ignition of an exterior wall assembly -Wall is exposed to a specified radiant heat flux during a 20-minute period. Shall NOT be used to: -Evaluate the fire endurance of wall assemblies -Evaluate effect of fires originating within the building, within the exterior wall assemblies, or at openings -Evaluate surface flame spread NFPA 285: Walls With Combustible Components -Method of determining the flammability characteristics of exterior, non-load-bearing wall assemblies. -Evaluates combustible components within walls of non-combustible construction. -Simulates the tested wall assemblies’ fire performance.

SECTION 1 What is NFPA 285? Test of the actual wall assembly is generally required when “noncombustible” walls contain “combustible” materials. Is not new, but awareness has increased due to code changes. In high-rise buildings: Assembly fire performance is critical for evacuation and life safety. www.bfm.co.th/index.php?m=product&a=index&lang=en High-Rises:  2010 - Recent exterior fires in China and the US from small ignition source can quickly spread to engulf the entire exterior. This is especially dangerous on high rise buildings due to limited rescue opportunities.   NFPA states that In 2005-2009, an estimated 15,700 reported “high-rise” structure fires per year resulted in associated losses of an average of 53 civilian deaths, 546 civilian injuries, and $235 million in direct property damage per year. An estimated 2.6% of all 2005-2009 reported structure fires were in high-rise buildings (NFPA). www.bfm.co.th/index.php?m=product&a=index&lang=en

History of NFPA 285 1970’s 1980’s 1990’s 2000’s 2010’s Energy Crisis: SECTION 1 History of NFPA 285 Energy Crisis: Leads to increased exterior insulation applications 1988: Uniform Building Code adopts UBC 17-6 1997: Uniform Building Code adopts UBC 26-9 2000: IBC begins requiring NFPA 285 testing 1970’s 1980’s 1990’s 2000’s 2010’s Late 70’s: SPI develops full-scale test Full-scale Fire Test UBC 17-6 / UBC 26-4 1998: NFPA adopts UBC 26-9 as NFPA 285 Reduced-scale Fire Test UBC 26-9 / NFPA 285 2012: IBC expands NFPA 285 testing to WRB 1970’s energy crisis: plastics industry (SPI) proposed the use of foam plastic insulation on/in exterior walls to increase energy efficiency but proposal rejected. Issue: Building Codes require Types I, II, III & IV construction to be of noncombustible construction but foam plastics are combustible Late 1970’s, SPI develops a full scale testing methodology to evaluate potential flame spread of foam plastics when installed on exterior walls. Late 1980, the UBC (Uniform Building Code) adopts the proposed test method (UBC 17-6, later renumbered UBC 26-4). Other building codes* also adopt similar versions of this code change by the early 1990’s. *3 legacy codes: BOCA National Building Code (BOCA/NBC) by the Building Officials Code Administration International (BOCA) Uniform Building Code ( UBC) by the international Conference of Building Officials ( ICBO0 Standard Building Code ( SBC) by the Southern Building Code Congress International (SBCCI) 1990’s: SPI creates a new test methodology -- a small scale version, which becomes adopted by the UBC (renumerated UBC 26-9), 1997. This test gets submitted to NFPA Committee on Fire Tests 1998 - NFPA adopts/ publishes this test as NFPA 285: Standard Fire Test Method for Evaluation of Fire Propagation Characteristics of Exterior Non-Load-Bearing Wall Assemblies Containing Combustible Components. And ICC IBC specifies NFPA 285 Source: “NFPA 285: What you Need to Know” by Jesse J. Beitel – JBED Summer 2012 issue

IBC NFPA 285 Testing - Material Triggers SECTION 1 IBC NFPA 285 Testing - Material Triggers Foam Plastic Insulation (Ch. 26) Applies to Type I – IV construction (~1988) Applies to buildings of any height Combustible Exterior Cladding (Ch. 14) EIFS - (~2000 IBC) MCMs - (~2003 IBC) FRPs - (~2009 IBC) HPLs - (~2012 IBC) Water-Resistive Barriers (Ch. 14) Applies to Type I, II, III, IV buildings over 40 ft Applies to combustible WRB’s - (2012 IBC) REQUIRED EIFS – Exterior Insulation Finishing Systems MCMs – Metal Composite Materials FRPs – fiber reinforced plastics (molded plastics) HPLs – High pressure laminate As of August 10, 2012, Maryland is the only state that has adopted the 2012 IBC. -DuPont BKC Research

Section 2: NFPA 285 Components and Parameters to Successful Test Performance

2 Story Test with Interior & Exterior Burners SECTION 2 NFPA 285 Multi-Story Test 2 Story Test with Interior & Exterior Burners Architectural Testing, Inc. – Informational Bulletin # 61

NFPA 285 Fire Test - Components SECTION 2 NFPA 285 Fire Test - Components 6” Concrete Slab 2nd Floor Room CMU Walls 8” Concrete Slab 1st Floor Room Room Burner Test Wall Assembly 18’ Tall x 10’ Wide 78” Wide Window Opening Window Burner

NFPA 285 Fire Test - Parameters SECTION 2 NFPA 285 Fire Test - Parameters No flame propagation in 2nd floor room

NFPA 285 Fire Test - Parameters SECTION 2 NFPA 285 Fire Test - Parameters Externally, Flames shall not reach 10’ above the window’s top Externally, Flames shall not reach 5’ laterally from the window’s centerline

. . . . . . . . . NFPA 285 Fire Test - Parameters SECTION 2 NFPA 285 Fire Test - Parameters . . . . . . . . . Inside wall assembly, Thermocouples shall not exceed 1000 ºF during the test.

Section 3: Combustible Components in a Noncombustible Wall Assembly

Building Envelope Assembly Components SECTION 3 Building Envelope Assembly Components Interior Drywall Vapor Barrier* Cavity Insulation Base Wall Structure Exterior Sheathing Air & Water Barrier Exterior Insulation Exterior Cladding * Vapor Barrier’s use and location in the wall is climate specific

IBC Combustible Component Requirements SECTION 3 IBC Combustible Component Requirements Air & Water Barriers –§1403.5 Combustible Claddings EIFS -§1408.2 MCM -§1407.10 FRP - §2612.5 HPL - §1409.10 Foam Plastic Insulation –§2603.5.5

IBC Combustible Component Requirements SECTION 3 IBC Combustible Component Requirements Foam Plastic Insulation Combustible Claddings (EIFS, MCM, FRP, HPL) Air & Water Barriers Design Conditions Requiring NFPA 285 Installations over 40’ (Type I, II, III, or IV) “Foam Plastic” and “Foam Plastic” core materials

Compliance NOT REQUIRED SECTION 3 IBC NFPA 285 Testing Requirements REQUIRED Is FOAM PLASTIC Insulation in the exterior wall assembly? YES NO YES Non-Combustible Construction Types I, II, III, or IV? (Per Commercial Building Code, IBC) Is EXTERIOR Installed greater than 40’ above grade CLADDING Combustible? AND YES NO Is WRB* Installed greater than 40’ above grade Combustible? AND Does not include type V construction XPS, EPS, Polyiso, or SPF? Is cladding EIFS, MCM/ACM, FRP, or HPL? HPL and Plastic veneer has exception allowing up to 50’ in areas 300sf or less and 4’ separation from other YES NO NO *PER 2012 IBC REVISION, EXCEPTIONS APPROVED FOR 2015 IBC RELEASE NFPA 285 Compliance NOT REQUIRED

IBC Combustible Component Requirements SECTION 3 IBC Combustible Component Requirements Foam Plastic Insulation Combustible Claddings (EIFS, MCM, FRP, HPL) Air & Water Barriers Material Requirements, IBC Type I-IV Taller than 40’ Products are Labeled and Identified by manufacturer Flame Spread Index ≤25 (ASTM E84) Smoke Development Index ≤450 (ASTM E84) Maintain assembly fire rating (ASTM E119 or UL 263) Separated from interior by a Thermal Barrier (gyp. bd) Class A

NFPA 285 Wall Assembly: Exterior Insulation SECTION 3 NFPA 285 Wall Assembly: Exterior Insulation Air & Water Barriers –§1403.5 Combustible Claddings EIFS -§1408.2 MCM -§1407.10 FRP - §2612.5 HPL - §1409.10 Foam Plastic Insulation –§2603.5.5

Climate Zones & Continuous Insulation Requirement's SECTION 3 Climate Zones & Continuous Insulation Requirement's Increasing Mandatory use of Continuous Insulation (ci) in EVERY climate zone ASHRAE 90.1 2010 Energy Codes are Changing to Reduced Envelope Loads Thermal insulation: − Higher Insulation R-value − Continuous Insulation (c.i.) [insulation that is continuous across all structural members without thermal bridges other than fasteners and service openings.] - Thermal bridges are regions of relatively high heat flow conductance in a building envelope Air Leakage Control: − Continuous Air Barrier − Building Envelope Airtightness

SECTION 3 Impact of Thermal Bridging on Effective Installed R-Value for Steel-Framed Walls 16” o.c. Thermal Bridging of Studs in the wall cavity. 24” o.c.

Most Common Continuous Insulation Types Used SECTION 3 NFPA 285 Wall Assembly: Exterior Insulation Common Insulation Types Most Common Continuous Insulation Types Used Glass Fiber Batt R-value: ~3.3 R/in Permeability: 118 perm-in Spray Polyurethane Foam R-value: ~6 R/in (high density)* Permeability: ~1.9 perm-in EPS (Expanded Polystyrene) R-value: ~4 R/in Permeability: ~2.7 perm-in XPS (Extruded Polystyrene) R-value: ~5 R/in Permeability: ~0.8 perm-in Polyisocyanurate R-value: ~6 R/in Permeability: ~0.75 perm-in Mineral Fiber R-value: ~4 R/in Permeability: ~54 perm-in Source: 2009 ASHRAE Handbook-Fundamentals, * 1997 ASHRAE Handbook-Fundamentals

NFPA 285 Wall Assembly: Combustible Claddings SECTION 3 NFPA 285 Wall Assembly: Combustible Claddings Air & Water Barriers –§1403.5 Combustible Claddings EIFS -§1408.2 MCM -§1407.10 FRP - §2612.5 HPL - §1409.10 Foam Plastic Insulation –§2603.5.5

NFPA 285 Wall Assembly: Exterior Cladding SECTION 3 NFPA 285 Wall Assembly: Exterior Cladding COMBUSTIBLE Exterior Insulation Finishing Systems (EIFS) Metal Composite Materials (MCMs) Fiber Reinforced Plastics (FRPs) High Pressure Laminates (HPLs) NON-COMBUSTIBLE Brick / Masonry / Stone / Terracotta Concrete / Cementitious Stucco Fiber Cement Boards / Panels Combustible Wide design aesthetic options Light-weight installation Minimal specialty tools required Many installations over 40’ must meet the requirements of NFPA 285 Many require sub-structure for attachment Non Combustible No NFPA 285 trigger (noncombustible) Ability to act as protective layer over combustible WRBs and Foam Plastics Generally higher costs Generally heavy materials

NFPA 285 Wall Assembly: Exterior Cladding SECTION 3 NFPA 285 Wall Assembly: Exterior Cladding Exterior Insulation Finishing Systems (EIFS) IBC regulates under “Foam Plastic” Requirements Meets the EIFS performance requirements of ASTM E2568 Metal Composite Materials (MCMs) Fiber Reinforced Plastics (FRPs) High Pressure Laminates (HPLs)

NFPA 285 Wall Assembly: Exterior Cladding SECTION 3 NFPA 285 Wall Assembly: Exterior Cladding Exterior Insulation Finishing Systems (EIFS) Metal Composite Materials (MCMs) Excludes “Foam Plastic” core materials Different core materials have different fire performance characteristics Available in Open and Closed Joint Systems Approximate 4mm-12mm panel thickness Fiber Reinforced Plastics (FRPs) High Pressure Laminates (HPLs) Factory bonded panel with metal faces and a plastic core. The systems include: joints, substructure and attachment methods

NFPA 285 Wall Assembly: Exterior Cladding SECTION 3 NFPA 285 Wall Assembly: Exterior Cladding Exterior Insulation Finishing Systems (EIFS) Metal Composite Materials (MCMs) Fiber Reinforced Plastics (FRPs) Foam cores comply with “Foam Plastic” Req’s Installations less than 40’ above grade Limited to 10% area when separation <10’ Flame Spread Index ≤200 (ASTM E84) Fireblocking Required High Pressure Laminates (HPLs) Composite materials consisting of reinforcing fibers impregnated with a polymer and then molded and hardened into the intended shape. Exterior panels are generally laminated onto a wood or plastic core. http://www.cranecomposites.com

NFPA 285 Wall Assembly: Exterior Cladding SECTION 3 NFPA 285 Wall Assembly: Exterior Cladding Exterior Insulation Finishing Systems (EIFS) Metal Composite Materials (MCMs) Fiber Reinforced Plastics (FRPs) High Pressure Laminates (HPLs) Available in Open and Closed Joint Systems Approximate 4mm-12mm panel thickness Different core materials have different fire performance characteristics Installations less than 40’ above grade Limited to 10% area when separation >5’ Decorative exterior grade pales with cellulous fibrous material bonded with a thermosetting resin by a high pressure process. Allowed to extend to 50’ in height when sections are limited to 400sf and separated 4’ vertically and not self ignite below 650 degrees F http://www.trespa.com

NFPA 285 Wall Assembly: Air & Water Barrier SECTION 3 NFPA 285 Wall Assembly: Air & Water Barrier Air & Water Barriers –§1403.5 Combustible Claddings EIFS -§1408.2 MCM -§1407.10 FRP - §2612.5 HPL - §1409.10 Foam Plastic Insulation –§2603.5.5

NFPA 285 Wall Assembly: Air & Water Barrier SECTION 3 NFPA 285 Wall Assembly: Air & Water Barrier COMBUSTIBLE Water Resistive Barriers (WRBs) Building Wraps Self Adhered Building Wraps Self Adhered Membranes Fluid Applied Membranes 2012 IBC: Installations over 40’ above grade must meet the requirements of NFPA 285 (Type I, II, III, or IV) 2015 IBC has approved WRB exceptions based on material properties and fuel load potential

NFPA 285 Wall Assembly: Air & Water Barrier SECTION 3 NFPA 285 Wall Assembly: Air & Water Barrier IBC NFPA 285 Test Requirements for WRBs Pre-2012 2012 2015 NFPA 285 Test Req’s None Installations over 40’ above grade must meet the requirements of NFPA 285 (Type I, II, III, or IV) Exceptions N/A 1. WRB is the only combustible wall component and the wall has a non-combustible covering (Table 1405.2) 2. WRB is the only combustible wall component and: -ASTM E84 Product Test: -flame spread index of 25 or less -smoke-developed index of 450 -ASTM E1354 (Cone Calorimeter)Product Test: -Incident radiant heat flux of 50 kW/m2. -Effective Heat of Combustion of less than 18 MJ/kg -Peak Heat Release Rate less than 150 kW/m2 -Total Heat Release of less than 20 MJ/m2 3. Windows and doors, and window/door flashings 2012 IBC: Code Adoption Process -Many states will adopt model codes statewide in its entirety, or adopt with their own amendments -“Home Rule” states, adopt model codes in each local municipality or add their own amendments -Some “Home Rule” states will adopt a recommended or minimum model code to guide the municipalities As of August 10, 2012, Maryland is the only state that has adopted the 2012 IBC. -DuPont BKC Research Regardless of slow adoptions rates, designing and specifying successful NFPA 285 wall assemblies is becoming more critical Class A

Section 4: Building Envelope Systems Part of NFPA 285 Compliant Assemblies

NFPA 285 Test Logistics Limited Testing Laboratory Availability SECTION 4 NFPA 285 Test Logistics Limited Testing Laboratory Availability Intertek (San Antonio, TX) Southwest Research (San Antonio, TX) Architectural Testing (York, PA) Potentially High Project Costs High Testing Cost Long Lead Time Results are owned by the company paying for the test No directory of listed assemblies No direct method for substituting assembly components  Product Selection  Planning in Design 3 labs nationally to test NFPA 285 assemblies   $50k-$60 per test, (Journal of Building Enclosure Design, Summer 2012) 6 weeks Min (curing time) 8-10 week standard lead time for a test ->Product Selection and Early design planning are critical to reduce costs and delays associated with NFPA 285 Assembly test results using other manufacturer’s product are owned and controlled by the company paying for the test

Wall Designs with Combustible Components SECTION 4 Wall Designs with Combustible Components Use existing NFPA 285 tested compliant system OR Test new assembly per NFPA 285 Modify an existing NFPA 285 compliant system with local Authority Having Jurisdiction (AHJ) approval, such as building officials

NFPA 285 Compliant Assemblies are Specific SECTION 4 NFPA 285 Compliant Assemblies are Specific Required for various components in all configurations For example, There is no one test or test assembly to qualify a WRB for use in all assemblies Changes in configurations (air gaps, attachment systems, etc.) can cause different results If a “New” combustible component is added in the wall assembly, then new testing required for all of the various configurations.

Variations in Wall Assemblies = Many Tests SECTION 4 Variations in Wall Assemblies = Many Tests WRB / Polyiso / Brick / MCM / HPL WRB / XPS WRB / XPS WRB / Mineral Fiber WRB/ Mineral Fiber WRB Over / Polyiso / Brick WRB Over / Polyiso / MCM / HPL WRB / Fiber Cement WRB Over / XPS / Brick WRB Over / XPS / MCM WRB Over / XPS / HPL / Stucco WRB Over / Mineral Fiber / Brick WRB Over / Mineral Fiber / MCM WRB Over / Mineral Fiber / HPL / EIFS

NFPA 285 Assembly Compliance Considerations SECTION 4 NFPA 285 Assembly Compliance Considerations Substitutions of one material for another can cause different test results Addition of combustibles (insulation, WRBs, etc.) can cause different test results Wall systems made of a number of previously NFPA 285 tested materials does not ensure a successful NFPA 285 test Tests are required for many various claddings and other combustible wall components – insulation, WRBs

Engineering Judgment Letter: WRB Example SECTION 4 Engineering Judgment Letter: WRB Example http://www.exponent.com Letter Expands Assembly Test Results by 4 Products Engineering Judgment Letter Analysis: WRB Example 1. Use WRB X in a successful NFPA 285 test 2. Develop fire performance parameters for WRB X (ASTM E1354 Cone Calorimeter) 3. Develop fire performance parameters for WRB Y 4. Compare fire performance parameters – if same or better, then maybe substitute Y for X in tested assembly

AIA/CES LU Learning Objectives Understand the Impact of the NFPA 285 Test in Relation to the International Building Code Apply the NFPA 285 Components and Parameters to Successful Test Performance Identify Combustible Components in a Noncombustible Wall Assembly that Trigger NFPA 285 Testing Design Building Envelope Systems as Part of NFPA 285 Compliant Assembly Variations

Thank you! Questions? DuPont™ Tyvek® AIA/CES LU This concludes the American Institute of Architects Continuing Education Systems Program DuPont Building Innovations DuPont™ Tyvek® Weatherization Systems