Insulated Panels

Systems
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Building to
the Power of

Property Insurer Fire Certification

Requirements

Contents
Introduction
Insurance Certification
Fire Test
Facts and confirmed research
Myths and Misinformation
Case study
Firesafe at a glance

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Introduction
Kingspan are world leaders in the research, development
and testing of fire engineered insurer approved firesafe
roof, wall, facade and temperature controlled (chill and cold
store) systems. This work has resulted in the development
and application of fire engineered technologies which
provide firesafe systems for building owners, occupiers
and tenants, enhancing property and business risk protection.
Kingspans firesafe solutions are based upon Factory Mutual
Global (FM) and the Loss Prevention Certification Boards
(LPCB) rigorous fire test and accreditation methods. FM
and LPCB systems are widely recognized by investors,
property insurers, designers and constructors for their
superior fire engineered performance thus reducing fire risks.
Kingspan believes that the only way to test any cladding
system is to perform a realistic scale test on the composite
product incorporating realistic joint details and fixings.
The new Euroclass Reaction to Fire Tests does not fully assess
panel performance and should not be taken in isolation.
Large scale fire tests such as those carried out by FM Global
and LPCB provide a better indicator of how panels will
perform in a real fire situation.

Insurance Certification
Factory Mutual Global (FM)
Approval Requirements
FM Global (FM), formally known as Factory Mutual, has a
severe test standard for assessing reaction to fire. This test
standard is FMRC 4880 (1994) Approval requirements for
Class 1 fire classification with no height restriction.

certs
APPROVED

Achievement of Class 1 with no height restriction is

dependent on performance in a number of tests that
include
ASTM E84 Surface Burning Characteristics
ASTM D482 Ignition Residue tests
ASTM E711 Oxygen Bomb tests
UBC 26-3 Room Test
FMRC Room Corner Test (25/50ft test)
The FM Global FMRC 4880 maximum 50 ft (15.24 metres)
height wall test is very severe. Two walls 15.24 m high
with a small ceiling are lined with panels and a large fire
source (345kg dry timber) is positioned in the corner. To
achieve approval there has to be no flame spread or fire
propagation to the extremities of the panel construction.
Kingspan FM approved panels are well within these limits
with no flame spread away from the fire source.

LPCB
The loss Prevention Certification
Board (LPCB) provides stringent
large scale fire testing,
certification, approval procedures
and guidance contained in the
LPCB Design Guide for the Fire
Protection of Buildings. These
require that the approved
systems/equipment are
fit-for-purpose when needed.

The building fabric is an important part of any insurance

assessment. Choice of an FM approved panel system or an
appropriate grade of LPCB approved panel will lead to -

No Additional Premium
No Additional Excess

Approved to LPS 1181

Certificate Nos. 186a, 260a & 279c
Approved to LPS 1208
Certificate No. 186b & 279b

Naas Fire Station

Naas

Project Name
Product
Colour
Usage

Naas Fire Station

KS1000 RW Roof Trapezoidal
Merlin
Emergency Fire Services

Insurer Certification Requirements

FM 50ft Room Corner Test
The images on these 2 pages show a sequence from
ignition to extinguishment of 200mm thick Kingspan IPN
panels. The fire load consists of 345kg red oak pallets. The
key pass fail criteria is that there is no lateral fire spread to
the edge of the enclosure and no ignition of the ceiling.
The Kingspan panels are well within these limits proving
that the panels do not promote the spread of fire.
As a result of this test, and other large scale tests
Kingspan wall, roof and ceiling panels are approved by
FM Global for use without any restriction in height.

Insurer Certification Requirements

Fire is contained in the room corner
- no evidence of fire propagation

LPS 1181 Fire Tests

Panels removed after LPC test show no spread of flame

Large Scale Fire Testing

-LPS 1181 Test
The key parameters of the test include:
Fully developed fire -1 mega watt fire load.
Max temp > 1,000 C at internal liner.
LPS 1181 test designed to assess flame spread, ignition
and promote flash over conditions.

Kingspan

results

Effect at 1,000 C internal surface temperature.

Stable protective char formed.
Char/core expands to fill any gap between facings,
consequently no voids.
Fire rated isophenic core. 70% unaffected, 30% char at
1,000 C.
No spread of flame, flashover or fire travel within the
core between the facings.
At high temperatures greater than 300 C protective
char forms.
Panels are unaffected away from main fire source.

Facts and Confirmed Research

Although the rigid isophenic used in the panels is
unsurpassed in its thermal insulating properties, it is
basically combustable, like all organic substances.
But the historical fire performance and insurance loss
statistics relating to the use of Kingspan isophenic (IPN)
panels in the external envelope has been excellent. There
is no evidence whatsoever to suggest that Kingspan
panel systems are not fit-for- purpose and there is no
link with higher insurer losses. This is proven by detailed
insurer loss statistics and case studies on fires in buildings
clad with such panels.
The following findings can be summarized from the
research carried out on many real fires where Kingspan
insulated roof and wall systems were in use:
The panels do not contribute to a fire. They are only
damaged in the immediate area of the fire and
self-extinguish after the fire load has gone
By forming a protective char layer, the fire is starved
of oxygen between the metallic skins of the panel.
The panels are thus self-extinguishing and do not
contribute to a fire.
Thermoset rigid isophenic (IPN) does not melt or drip
when exposed to fire. Thus, the danger of igniting
secondary fires does not arise.
The gases given off when isophenic foam burns are
less toxic than those given off by conventional building
materials (e.g. wood)
When used as roof cladding, the sandwich panels resist
the spread of fire and reduce radiant heat
The additional fire load caused by isophenic panels
varies between 3 and 6 kWh/m2 and therefore has very
little effect on a fire. This very low value results from
the low density of the insulating foam core which is
approximately 41 kg/m3
The results from the standardised tests used to
determine combustibility are confirmed completely by
the behaviour of the panels in practice

Conclusion
The behaviour of KINGSPAN insulated roof and wall
panels in a fire is similar to that of other fire-resistant
building materials.
With respect to current fire regulations and the need to
build passive fire protection into a structure, insulated
isophenic panel systems are amongst the safest proven
building methods.

Myths & Misinformation

Combustibility of installed
panel systems

Combustibility of Real-Life Panel

Installations

In recent years, huge confusion has been caused by panel

manufacturers and their suppliers making claim and
counter claim about the non-combustibility or otherwise
of their own and their competitors panel systems.

The reality is that all panel systems have varying levels

of combustibility because all contain combustible
materials. The only reliable way of assessing panel system
combustibility is to base a judgement on testing the
entire system. Tests and standards such as LPS 1181,
LPS 1208 and FM 4880 are ideal in this respect. The
varying levels and grades of performance defined by
these tests allow the specific panel system performance
to be matched to the specific risk.

ABI Definitions of Construction 2003

(ABI - Association of British Insurers)
The following table outlines the ABIs
Definitions of Construction
Denition

Description

FIRE RESISTING

All elements of construction

(including oors) to be noncombustible and achieve
at least 90 minutes re
resistance

NON COMBUSTIBLE

All elements of construction

to be non-combustible
OR approved to LPS 1181
INCLUDES KINGSPAN
FIRESAFE IPN

PARTLY COMBUSTIBLE

Any building having from

10% up to 35% construction
elements of combustible
construction.

COMBUSTIBLE

Any building having between

35% and 70% of combustible
materials in the elements of
construction.

HIGHLY COMBUSTIBLE

Any building having over 70%

of combustible materials in
their element of construction

The real issue is not directly related to the combustibility

of the panel system core - all have combustible elements.
The real issue is related to how a specific system will
perform in a real fire scenario and whether it acts as noncombustible building element by not contributing to fire.

Ignitability of Polystyrene
Polystyrene is a thermoplastic this means that heat will
cause the material to melt and form a liquid. This liquid
is highly flammable and easily ignites. This performance
is in stark contrast to isophenic a thermosetting material,
which forms a strong carbonaceous char protecting
the core from further attack.

A propane torch reduces polystyrene to flammable gas and liquid in seconds

Myths & Misinformation

Ignitability of Kingspan Fire Rated IPN
One concern raised by insurers is the potential for
exposed insulation in real situations. The reality is that
any insulation panel system is likely to be damaged or
modified after installation and this may lead to exposure
of the core and example would be where a hole has
been cut in the panel for new pipework, ductwork or
electrical services. Such modifications are often not
finished correctly and are perceived to provide an easy
entry point for fire. The question is how big is the risk?
The fact is that Kingspan approved IPN is very difficult
to ignite. The images below cover the effect of a high
intensity propane torch on exposed IPN after the metal
facings have been removed. The propane torch generates
a temperature of over 1000C. The images show the effect
after 30 minutes exposure and are a good demonstration
of how the IPN forms a strong carbonaceous char that
protects the core foam from ignition. When the burner is
removed after 30 minutes the core self extinguishes.
Good practice dictates that any panel damage is repaired
or site modifications are installed correctly however,
the propane torch test does demonstrate that insurer
approved IPN does not ignite and the exposed core does
not present a fire hazard.

After 30 minutes at over 1000

Section cut through the thickness of the panel after

30 minutes exposure showing that the char occurs only
in the area of direct flame impingement and there is
no fire propagation.

Case Study
Wharfedale Hospital, 5th July 2003

Conclusion

This is the first recorded fire in a building clad in LPCB

approved isophenic panels. This fire occurred in an
extension to the hospital under construction. An arsonist
ignited a solvent based adhesive poured over a large
pile of combustible building materials that was stored
in the ground floor of the facility. The ground floor was
essentially open with the external cladding starting at the
first floor level.

The Tenos report concludes In spite of significant

heat generated by the fire (sufficient to damage the
intumescent coating and distort the steel beams); the
orientation of the cladding panels directly above the fire;
and the fact that the fire stopping was not in place; the
cores of the panels as evidenced by photograph 2, 3 and
4 did not ignite; did not promote fire spread within the
core or to the eaves and did not significantly contribute
to the products of combustion.

Kingspan commissioned Tenos to perform an

independent investigation into the fire. This involved a
visit to site and discussions with the Fire & Rescue Team.
A detailed report is available.
Image 1

Image 1
Side of the building exposed to direct flame
impingement and smoke/heat damage from the ground
floor. It is clear that the IPN core has not ignited and has
played no role in the fire.
Image 2
The side of the building that experienced a bigger fire
attack. Flames appear to have risen to the eaves
a height of approximately 10 metres. The external steel
sheet has bowed and delaminated in the areas of flame
impingement however, there is no indication the fire
has spread through the cladding.
Sections were cut out of the short panels in the middle
of this photograph in order to inspect the steel column
behind the panels. The next photograph shows this more
clearly.
Image 3
Close-up of the inspection holes cut in the panel
after the fire. The insulation core can be seen clearly
and looks to be virtually unaffected by the direct flame
impingement on the outer steel facing. The steel column
was not affected.
Image 4
A panel that has been exposed to direct flame
impingement on the outer sheet. The metal has been
pulled away by contractors to inspect the isophenic
core. It is clear that the insulation core has been almost
unaffected by the fire. Only light charring can be seen.

These photographs provide a record of the damage and

include some explanatory comments.
Image 2

Image 3

Image 4

Protecting business and property

with
insurer approved systems

Look for the logo

KINGSPANS RANGE OF FIRESAFE ISOPHENIC (IPN) PANELS

Firesafe is Kingspans range of insurer approved panels

These panels with a sophisticated Isophenic core will not promote fire spread,
are self extinguishing and give off minimal smoke in a real fire situation
The most important way of distinguishing between different panel systems
is through fire testing. Building regulation tests are important in this
respect but it must always be remembered that the key objective of building
regulation guidance is to ensure that personnel can leave the building safely
in the event of a fire. (EI resistance tests)
Property conservation is not a key consideration to regulators In stark
contrast to insurers and investors!
Kingspan believes that the only way to test any cladding system is to perform
a realistic scale test on the composite product incorporating realistic joint
details and fixings.
The new Euroclass Reaction to Fire Tests do not fully assess panel
performance and should not be taken in isolation.
Insurers recognise the limitations of the small scale reaction to fire tests used to
demonstrate compliance and have developed their own tests such
as FM & LPCB
Insurance certificates available are FM Global & LPCB
FM Global is an American insurance agency which carries out stringent large
scale fire tests. Kingspan has FM unlimited approval which means the panels
can be used on buildings of unlimited height
Even clients not insured by FM Global will request FM standard products
because of their stringent product testing.
LPC was purchased by the Building Research Establishment (BRE) from
ABI (Association of British Insurers) & Lloyds in 2000. LPCB provide
research, testing and Fire test Approvals. LPS 1181 is a wall and ceiling test
for insulated panels. LPCB are promoting the LPS 1181 test across Central
Europe.
External claddings that are LPCB approved to LPS1181 can be classed as
non-combustible building, Association of British Insurers (ABI) May 2003
Kingspans unique firesafe blend is a patented formula which can not be
copied by our competitors.
If you would like to see a fire test on our Firesafe Isophenic panels please
contact any Kingspan office

Identification Plaques
Fire officer and insurance surveyor identification plaques
are used for rapid identification of building fabric
Kingspan maintain a project register of all buildings
constructed with
roof and wall systems
identified by a special registration number.
Kingspan
labels are avaiable for attaching to
the building to assist property insurers and the brigades.
Labels are available on request.

KINGSPAN PANELS PROFILES

Wall & Facade Systems - horizontal / vertical
EXTERNAL PROFILATION
For panels with isophenic or mineral fibre insulation

10

40
1

10

E (euro)

17,5

40

17,5

50

8,75

50
1

40

M (micro)

0,75

B (box)

For panels with isophenic insulation only

12,5

24,5

16

299

25

16

299

1,5

24,5

N (mini micro)

1,5

0,8

R 52

50

S (segment)

8
1

L (tramline)

W (wave)

INTERNAL PROFILATION
For panels with isophenic or mineral fibre insulation
B (box)

MB (minibox)

40

10

40

F (flat)

10

40

33,33

33,33

33,33

Roof Systems - pitched / flat

Panels with isophenic insulation

RW

SM

XD
Panels with mineral fibre insulation

FF

SX

RT
Rooflight panels

RM

Please consult the colour range with Kingspan Technical Design Bureau.
* KS 1000 RW can be used as wall panel

RW / GRP MK1

RW / GRP MK3

Kingspan Limited
Czech Republic: Telephone: +420 495 866 111, Fax: +420 495 866 100, Email: info@kingspan.cz
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Poland: Telephone: +48 48 378 31 00, Fax: +48 48 378 13 30, Email: info@kingspan.pl
Lithuania: Telephone: +370 37 451 883, Fax: +370 37 451 885, Email: info@kingspan.lt
Hungary: Telephone: +36 29 573 400, Fax: +36 29 573 401, Email: info@kingspan.hu
Romania: Telephone: +40 21 231 50 89, Fax: +40 21 231 50 89, Email: info@kingspan.ro
Croatia: Telephone: +385 1 464 80 51, Fax: +385 1 464 80 52, Email: info@kingspan.hr
Serbia: Telephone: +381 24 671 525, Fax: +381 25 535 057, Email: info@kingspan.co.yu
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