CHAPTER 12

SECTION 10

Sprinkler Systems for Storage Facilities

James E. Golinveaux Joseph B. Hankins

his chapter addresses sprinkler system protection for storage operations. It is an unfortunate fact that many of the factors that enhance the efficiency of a storage facility also increase the fire risk presented by that storage. The more efficiently storage volume is used, the more combustible materials there are in that volume, and the more material there is to burn. Access to the stored materials requires space between storage units. Efficient use of storage space requires that these spaces (flues) be as small as possible. The result is an array that could hardly be any more conducive to maximum burning rate and fire spread than if it had been designed with that purpose in mind. Therefore, well-designed, properly installed, and carefully maintained fire protection is critical if a catastrophic fire is to be avoided. This chapter reviews basic fire protection principles primarily in the context of NFPA sprinkler system and storage standards. It begins with a discussion of commodity classification and storage arrangement, height, and clearance and then discusses sprinkler systems and associated design factors unique to storage operations. Then it presents an overview of special commodities and special storage facilities. The remaining sections highlight other fire protection features that a comprehensive fire protection program needs and construction. This chapter covers fire protection for a broad range of materials and storage arrangements, but it does not discuss the protection of special hazards such as flammable liquids and gases, explosives, and so on, which is found in Section 8, Chapter 6, Flammable and Combustible Liquids; Section 8, Chapter 7, Gases; and Section 8, Chapter 14, Explosion Prevention and Protection.

include NFPA 230, Standard for the Fire Protection of Storage, and NFPA 13, Standard for the Installation of Sprinkler Systems. For the most part, sprinkler systems are the backbone of an effective fire protection strategy for storage facilities. NFPA storage standards are based on full-scale fire tests and past loss experience. The standards address storage situations in which test data are available or in which conclusions could be drawn from the extrapolation of available data, judgment, or experience. For storage situations beyond the scope of a specific NFPA document, engineering judgment and other sources may be used but only with care and by professionals with an in-depth knowledge of fire protection science and practice. NFPA storage documents and this chapter outline basic fire protection concepts for storage operations and can provide guidance where specific standards are not available. To effectively prepare a fire protection plan for a storage occupancy, the following steps should be followed: Determine the commodity classification Identify the storage arrangement Establish the storage height and clearance from top of storage to sprinklers Develop a protection scheme (automatic sprinkler system) In addition to the basic steps just outlined consideration also is needed for: Water supply Special commodities Special storage facilities Supplemental means of fire protection Construction

NFPA STORAGE STANDARDS

NFPA standards outline methods for providing effective fire protection for various types of storage occupancies. These standards

COMMODITY CLASSIFICATION
Proper design of sprinkler systems requires that the commodities to be stored be identified and categorized according to their burning characteristics. Categorizing commodities is a difficult task because a wide variety of products can be found within stored commodities. The classification of a commodity is based on a unit of storage of the commodity. For the most typical commodities, the unit of storage is the pallet load and includes the pallet, the packaging of the commodity, and the commodity itself. Commodity classification does not take into account mixed storage of commodities. For example, a storage area containing pallet loads of paper products, which are Class III commodities, mixed with

James E. Golinveaux is the senior vice president of research and development for Tyco Fire Products in Cranston, Rhode Island. He is a member of NFPAs Technical Committees on Automatic Sprinkler Systems, Parking Structures, and the Industrial Storage and Miscellaneous Occupancies. Joseph B. Hankins is a senior engineer in the fire and explosion section of staff engineering at Factory Mutual Global in Norwood, Massachusetts. He is a member of NFPAs Technical Committee on Automatic Sprinkler Systems.

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pallet loads of Group A plastic commodities cannot be classified as Class IV storage based on the relative number of pallet loads of each commodity. The most challenging commodity (highest class number) determines protection for everything in an undivided, unseparated area. The paper products must be protected as a plastic commodity, unless the commodities are separated and each is properly protected. The reason for this is quite simple. The fire tests on which NFPA 13 is based involve no more than a 200 ft2 (18.6 m2) fire area. Fires that were not confined to that size by sprinklers were typically not controlled. So the severity of a fire in mixed commodity storage is dictated by where the fire starts, not the overall mix of commodities. And, since any point of origin is possible, the most challenging pointnear the most challenging commoditiessets the need for protection of the entire space. Classifications reflect the burning rate and heat release rate of a commodity, as well as the effect of water (from sprinklers) on the commodity. For this reason, small-scale tests, which measure heat of combustion or relative horizontal burning rates, are of little use in determining commodity classification. Full-scale fire tests can be used to determine commodity classification, but full-scale tests can be quite expensive. Intermediate-scale test methods (such as the fire products collector commodity classification method developed by Factory Mutual Research and used by FM Global and Underwriters Laboratories) provide a more economical means to accurately determine commodity classification. NFPA 13 provides an approach that categorizes materials into one of seven major categoriesClasses I through IV and Groups A, B, and C plastics. (NFPA 13 contains a comprehensive list of commodities and their classifications.) The definitions of the various commodity classifications are as follows: Class IClass I commodities are noncombustible products in corrugated containers with or without single-thickness cardboard dividers, stored on wood pallets. The standard Class I test commodity is glass jars in compartmented cardboard cartons on wood pallets. Class IIClass II commodities are Class I products with slightly increased amounts of combustible packaging (such as multiple-layer cartons) or trim (such as plastic knobs). The standard Class II test commodity is a metal-lined double triwall corrugated carton on a wood pallet (Figure 10.12.1). Class IIIClass III commodities include ordinary combustibles (wood, paper, natural fiber cloth) in cardboard cartons on wood pallets. The standard Class III test commodity is paper cups in compartmented cardboard cartons on wood pallets. Class IVClass IV commodities are Class I, II, or III products containing limited amounts of Group A plastics in corrugated cartons and Class I, II, and III products in ordinary corrugated cartons, with limited amounts of expanded Group A plastic packaging on wood pallets. Limited amounts of Group A plastics are considered to be 5 to 15 percent by weight and 5 to 25 percent by volume. The standard Class IV test commodity is a mixture of paper and plastic cups (15 percent plastic by weight) on wood pallets.

FIGURE 10.12.1 Standard Class II Test Commodity (Source: Underwriters Laboratories Inc.)

Classification of Class I through IV commodities is based on the assumption that they are stored on wood pallets. If plastic pallets are used, testing has shown that the commodity classification must be increased one level. For example, wood or paper products that would be considered a Class III commodity when stored on wood pallets must be protected as a Class IV commodity when stored on plastic pallets. This can complicate the decision to convert from wood pallets to plastic pallets in storage areas, as the existing sprinkler protection probably will no longer be adequate and will require modification. However, there now exist listed plastic pallets that can be treated as standard wood pallets for determining the commodity type.

Plastics
Plastics present a greater fire protection challenge because their combustion can produce about 1 to 3 times as much heat per unit of weight as wood or paper. In addition, plastics can burn at a much faster rate, resulting in a very challenging, high heatrelease rate fire. Plastic materials are categorized in NFPA standards into one of three groups: A, B, or C. Group A plastics present the most severe hazard (Figure 10.12.2), whereas Group C plastics present the least severe. Group B plastics behave similarly to Class IV commodities, and Group C plastics behave similarly to Class III commodities. The following list identifies a number of plastics according to their potential fire severity. The list contains unmodified plastic materials. Although fire-retardant modifiers and other additives can inhibit ignition, once ignited, heat release is usually the same as for unmodified plastic. Intermediate or full-scale testing is the best means to determine a modified materials classification.

CHAPTER 12

Sprinkler Systems for Storage Facilities

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Group C Fluoroplastics (PCTFEpolychlorotrifluoroethylene,PTFE polytetrafluoroethylene) Melamine (melamine formaldehyde) Phenolic PVC (polyvinyl chloriderigid or lightly plasticized, e.g., pipe, pipe fittings) PVDC (polyvinylidene chloride) PVF (polyvinyl fluoride) PVDF (polyvinylidene fluoride) Urea (urea formaldehyde) In determining the classification of a commodity that is a mixture of different materials, the amount of the most hazardous material and its effect on a fire must be considered. If the most hazardous material dominates the behavior of the burning commodity, then the product must be classified the same as the most hazardous material. For instance, thick, expanded, Group A, plastic packing material surrounding a Class IV commodity in a corrugated carton will completely dominate the fire behavior in the early stages of the fire, when the protection battle is won or lost. So the commodity must be classified as an expanded Group A plastic.

FIGURE 10.12.2 Nonexpanded Group A Test Commodity16-oz Polystyrene Plastic Jars Individually Separated by Cardboard (Source: Underwriters Laboratories Inc.)

Group A ABS (acrylonitrile-butadiene-styrene copolymer) Acrylic (polymethyl methacrylate) Acetal (polyformaldehyde) Butyl rubber EPDM (ethylene-propylene rubber) FRP (fiberglass-reinforced polyester) Natural rubber (if expanded) Nitrile rubber (acrylonitrile-butadiene rubber) Polybutadiene Polycarbonate Polyester elastomer Polyethylene Polypropylene Polystyrene Polyurethane PVC (polyvinyl chloridehighly plasticized, e.g., coated fabric, unsupported film) SAN (styrene acrylonitrile) SBR (styrenebutadiene rubber)

STORAGE ARRANGEMENT
Storage configuration has a major impact on how a potential fire burns. Therefore, a commoditys storage arrangement must be considered when preparing the fire protection plan. Materials are most commonly arranged as bulk storage, solid pile, palletized pile, or rack storage. Bins and narrow shelves also are used, more commonly in smaller stockrooms holding moderate quantities of product. Most warehouses combine these various storage arrangements. The most critical factor among the various storage arrangements that affect fire behavior and the difficulty of controlling a fire is the presence of flue spaces. Storage configurations create these horizontal and vertical air spaces. Air passes through flue spaces, oxidizing the fire. Although flue spaces are not desirable, they should not be obstructed when present. Obstructed flue spaces can prevent heat and combustion products from reaching a fire detector or sprinkler and also can prevent water or other fire protection mediums from reaching the fire.

Bulk Storage
Bulk storage consists of piles of loose, free-flowing materials, including powder, granules, pellets, or flakes, and agricultural items, such as peanuts. The materials are typically stored in silos, bins, tanks, or in large piles on the floor. Flue spaces are typically not present. Fires in large piles tend to burrow down into the pile, making them difficult to extinguish. This type of fire requires prolonged soaking to reach the seat of the fire. Bulk storage arrangements are also subject to spontaneous ignition. Fires starting inside the piles are difficult to locate, unless heat sensors immersed in the pile continually monitor internal heating.

Group B Cellulosics (cellulose acetate, cellulose acetate butyrate, ethyl cellulose) Chloroprene rubber Fluoroplastics (ECTFEethylene-chlorotrifluorethylene copolymer, ETFEethylene-tetrafluoroethylene copolymer, FEPfluorinated ethylene-propylene copolymer) Natural rubber (not expanded) Nylon (nylon 6, nylon 6/6) PET (thermoplastic polyester) Silicone rubber

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Material handling equipment, such as belt conveyors, airfluidizing ducts, and bucket conveyors (legs) are often employed to transfer the material to and from its storage location. This moving process agitates and disturbs material. Airborne combustible material presents an explosion hazard. This concern is significant, especially in grain storage facilities. In addition, conveyor belts and other components can be combustible and can burn together with the commodity in inaccessible places high above the floor, in tunnels, and in housings around conveying equipment.

Solid Pile Storage

Solid piling consists of cartons, boxes, bales, bags, and so on in direct contact with each other. Air spaces, or flues, exist only where contact is imperfect, or where a pile is close to, but not touching, another pile. Because pallets are not typically used, stacking is done by hand or by lift trucks using side clamps or prongs, which are pried between packages or bales without damaging the product. Figure 10.12.3 illustrates a type of solid piling in which spaces left between cartons accommodate lift-truck prongs. Wide aisles give the lift truck plenty of room to maneuver. The dark pipes at the ceiling are sprinkler lines. Relative to palletized and rack storage arrangements, solid piling gives fire the least opportunity to develop and spread due to restricted air access for burning, resulting in a fire challenge less than that for palletized or rack storage. Still, high piling presents a significant fire hazard, especially where the piles surface consists of a material susceptible to rapid flame spread properties. Also, the higher the pile, the more difficult it is to break up and separate during a fire.

quately support other pallet loads so that the commodity is not crushed or so the pile does not become unstable. Due to these considerations, the maximum height of palletized storage usually does not exceed 30 ft (9.1 m). Pallets contain open horizontal spaces for forklift trucks. These horizontal spaces make this storage arrangement functional, but they increase the fire hazard. Air spaces usually continue in one direction along the entire width of a pile. Like vertical flue spaces, horizontal spaces let air easily pass to the fire. In addition, their configuration lets a fire burn in the space while shielding it from the water from an overhead sprinkler system. Early fire collapse can be a positive factor in protection of solid pile and palletized storage, but the key word is early. In order for early pile collapse to be a positive factor for fire protection, it must occur within 2 to 3 minutes of the time the first sprinkler operates. Almost any commodity in solid pile storage will ultimately collapse, but credit can be given only if it can be assured that early pile collapse will occur. In general, the great majority of stored commodities will not qualify for credit for pile collapse.

Rack Storage
A storage rack is a structural framework in which a commodity is placed, usually as a pallet load. The design of rack storage systems maximizes vertical storage capability. The ceiling height or the vertical reach of materials-handling equipment limits storage heights. Some rack storage arrangements are over 100 ft (9.3 m) high. The most common racking configurations are single-row and double-row racks. Single-row racks include racks up to 6 ft (1.83 m) wide, separated from other storage by at least 3.5-ft (1.07-m) aisles. Double-row racks consist of two single-row racks placed back-to-back, with a combined width up to 12 ft (3.66 m) and aisles at least 3.5 ft (1.05 m) wide on each side (Figures 10.12.4 and 10.12.5). Multiple-row racks, which can

Palletized Pile Storage

Palletized storage consists of unit loads placed on pallets that are then stacked on top of one another. A pallet load usually takes the form of a cube, with dimensions of about 4 ft to 5 ft (1.22 m to 1.52 m) in height, and consists of a single package or multiple packages. The top surface of the pallet load must ade-

Conventional pallet

Commodity

Floor Section view Possible transverse flue spaces End view No longitudinal flue space is necessary Rows of storage No longitudinal (back-to-back clearance) flue space Plan view

FIGURE 10.12.3

Example of Solid Pile Storage

FIGURE 10.12.4 Back Loads

Typical Double-Row Rack with Back-to-