INTRODUCTION
FLAMMABILITY OF NFRC
Polymer Flammability
Polymer matrix
Thermoplastic Thermoset
Fiber PP PE PA66 PS PVC Epoxy PET Vinylester Phenolic
Cellulose* X X X X X X
Flax X X X
Jute X X X X X X
Sisal X X X X X
Kenaf X X X
Ramie X
Hemp X X X X
Bagasse X X
Bamboo X X X
Pineapple X X X
Wood flour/fiber X X X X X
Wool X
*Includes cotton.
gases, including carbon dioxide, hydrogen halides, and others. The actual
volatiles produced depend on the chemical nature of the polymer.
Flammable volatiles formed come into contact with oxygen to produce
highly reactive H and OH radicals, which are involved in the
further decomposition and the sustained burning of the polymer. Some
polymers may breakdown completely during thermal decomposition,
whereas others may form carbonaceous or inorganic residues. The
decomposition products, rate, and mechanisms of thermal decomposition
depend not only on the chemical composition of the polymer but also on its
physical properties [21].
Physical properties, such as glass transition, melting, and decomposition
temperatures, influence the thermal decomposition processes, as it is at these
temperatures that the polymer undergoes phase transitions, which result in
changes in physical properties, such as thermal conductivity, viscosity,
density, and modulus [19]. In the case of many aromatic thermosetting
polymers, the decomposition temperature is lower than the melting
temperature and therefore resulting physical transformations before
decomposition are minimal [21].
The limiting oxygen index (LOI), measured according to ASTM D-2863
[22], is often used to illustrate the relative flammability of different polymers
and, within the parameters of the LOI test, a polymer with a higher LOI
would have lower flammability than one with a lower LOI [19,23]. LOI values
of some commonly used polymers are given in Table 2 [19,23–25].
From the LOI values presented in Table 2, polyvinyl chloride, with a LOI
value of 23–45, would appear to be suitable for use as a matrix polymer from
a flammability point of view. When it burns, however, polyvinyl chloride
produces a heavy smoke and corrosive hydrogen chloride gas, and this
precludes its use as a matrix material for composites for end-use in ships and
aircraft [26,27]. Generally, the LOI as a measure of polymer flammability
should be used with caution because in real fire situations factors, such as
lower oxygen accessibility and higher air velocity and temperatures,
compared to those used in the LOI test according to ASTM D-2863
method, can influence the LOI of the polymer [19]. In addition, there is little
correlation between LOI and other fire properties, such as the heat release
rate (HRR) [28], smoke density, and others.
The formation of char during burning is an important criterion in gauging
the flammability property of a matrix polymer. Polymers, such as phenolics,
which are highly cross-linked, polyvinyl chloride, in which cross-linking may
occur during the decomposition process, and casein, a protein-based
biopolymer, form char during combustion [18,21,29]. The char is formed
at the expense of possible flammable volatiles, and it also acts as a
heat barrier between the heat source and lower layers of the polymer.
Note: Where a range of values is given, the higher value generally refers
to grades with mineral or glass–fiber filler and/or fire retardant.
Type Examples
Bast Flax, hemp, kenaf, jute, ramie
Leaf Pineapple, banana, sisal, agave, palm
Grasses Bamboo, bagasse, reed, wheat, rice
Fruit Luffa, coir
Wood Hardwoods, softwoods
Seed Cotton, kapok
The type of natural fibers available for use in NFRC is vast, examples of
plant-based fibers are shown in Table 3 [31]. Natural fibers are nonthermo-
plastic and as such their decomposition (pyrolysis) temperature is less than
their glass transition and/or melting temperatures [32]. Unlike protein fibers,
plant fibers has poor fire resistance; cotton, for example, has a LOI value of
18–20, whereas wool has a LOI value of 25 [19]. Consequently, there has been
more research into the flammability of plant fibers, notably cotton.
The thermal degradation of plant fibers involves a number of processes
including the desorption of adsorbed water, cross-linking of cellulose chains
with the evolution of water to form dehydrocellulose, decomposition of the
dehydrocellulose to yield char and volatiles, formation of levoglucosan, and
decomposition of the levoglucosan to yield flammable and nonflammable
volatiles and gases, tar, and char [10,32,33].
The thermal degradation of flax, sisal, and jute fibers, using thermogravi-
metric analysis (TGA), was reported by Manfredi et al. [30]. They found that
the thermal degradation of sisal and jute was similar, with the main peak at
3408C, whereas the flax started to degrade at higher temperatures, with
the main peak at 3458C. Slight variations in the flammability of different
plant fibers can be attributed in part to the chemical composition of the
fibers. Natural fibers are composed primarily of cellulose, hemicellulose, and
lignin, with the balance being made up of pectins, water soluble compounds,
waxes, and inorganic, nonflammable substances, which are generally referred
to as ash. Examples of the chemical composition of some plant fibers are
shown in Table 4 [31].
The decomposition of cellulose, between 2608C and 3508C, results in the
formation of flammable volatiles and gases, noncombustible gases, tars, and
some char [32,34–36]. A high content of cellulose tends to increase the
flammability of the fiber. Hemicellulose decomposes between 2008C and
2608C but forms more noncombustible gases and less tar than cellulose.
Composite Flammability
Flashover
Temperature
Smoldering Decay
/ flaming
Time
Heat flux: Low 20–60 kW/m2 > 50 kW/m2
Temperature: 600– 700 K 700– 900 K > 900 K
Ventilation: High High Low
Figure 1. The stages of a typical fire and some fire properties at various stages (redrawn
from Schartel and Hull [49], Karlsson and Quintiere [50], and Fitzgerald [51]).
ventilation – the fire is still controlled by the fuel, and large flames (10–100 cm).
The transition to a fully developed fire is known as the flashover point, and
this may occur at temperatures in the region 773–873 K. A fully developed
fire is characterized by high ambient temperatures (4900 K), high external
heat flux (450 kW/m2), low ventilation – oxygen availability is now the
limiting factor, and large flames (4100 cm). The fully developed fire
continues until the fuel source is depleted. The fire will then enter a
period of decay, when temperatures drop, and eventually it will extinguish.
The properties of a fire, such as heat flux, therefore, vary considerably
during the course of a fire and consequently the flammability properties of
the composite will also vary. Scudamore [52] has shown, in cone calorimeter
testing, that the effect of thickness on TTI is largely negated at higher heat
fluxes (75 and 100 kW/m2). The availability of oxygen can also influence
TTI – increasing or decreasing the TTI depending on the oxygen
concentration and makeup of the composite [28].
mineral fillers [55,56] and flame retardants for specific polymers such as
polyolefins [57], polystyrenes [58], and poly vinyl chlorides [59]. The flame
retardancy of textiles [60–62], including natural fibers, and composites
[15,17,18,20] have also been reviewed. In this review, we will specifically
examine some recent methods from the literature that have been or could be
employed for improving the fire resistance of NFRC.
Polymer Matrix
AMMONIUM POLYPHOSPHATE
Ammonium polyphosphate (APP), [NH4PO3]n, has been in use as a flame
retardant for many years [26,63]. It has found use in intumescent systems
and as an additive in plastics, paper, textiles, and so forth. When heated,
APP is reported to decompose in three stages, starting at around 1658C [64].
During decomposition, ammonia and water are evolved, and polymeric
phosphoric acid and phosphorous oxides are formed [63,64]. In most
polymers, APP acts mainly in the condensed phase where acid catalyzed
dehydration reactions and cross-linking promote char formation [20,63]. In
some polymers, APP may also act in the gas phase [20]. Phosphorus radicals
are released from the polymer at temperatures below that required for
decomposition of the polymer. The radicals terminate the combustion
process by reacting with H and OH radicals in the flame. In addition,
heavy phosphorus-containing volatiles may form a vapor-rich phase at the
polymer surface that restricts oxygen access. Matkó et al. [13] investigated
the flammability of different NFRC using APP as a polymer additive. In a
polypropylene/wood flake composite containing either 10% or 20% APP,
they found that with the addition of 10% wood flake, the LOI increased
slightly compared to that of pure polypropylene. There were hardly any
changes in the LOI when the level of wood flake was increased between 10%
and 40%, but at 50%, the LOI values were 30% and 32% for the composites
with 10% and 20% APP, respectively. The 20% APP samples performed
slightly better compared to the 10% APP samples. They also compared
polyurethane composites having either corn shell or wood flake as a filler.
Incorporation of 20% APP in the composites increased the LOI value from
20% to 27% for the corn shell composite and from 23% to 31% for the
wood flake composite. They concluded that the polyurethane acted as a
char-forming agent that contributed to improved flame retardancy. They
also showed that the LOI value for a plasticized starch-based biopolymer
can be increased from 23% to 33% by the addition of 10% APP. The LOI
value can be further increased to 60% by the addition of 30% APP. The
polyol nature of the matrix and plasticizer contributed to the improved
flammability through char formation.
EXPANDABLE GRAPHITE
Expandable graphite (EG) expands up to 300 times its initial volume at
around 9008C [65,66]. The flameless oxidation of the expanded graphite
consumes oxygen that results in the smothering of flames. The expanded
graphite also acts as a heat insulating layer and reduces dripping. Schartel
et al. [66] compared the thermal behavior and fire response of polypropy-
lene/flax composites using either EG or APP as the flame-retardant additive.
In TGA, all samples showed two-step decomposition: the first being
decomposition of the flax and the second for decomposition of the
polypropylene. The addition of 25% APP to the composite in place of
polypropylene resulted in the first-step decomposition occurring at a lower
temperature (a decrease of around 558C) and the second-step decomposition
occurring at a higher temperature (an increase of around 98C). The higher
temperature of the second-step decomposition was attributed to the
formation of a heat insulating char. The addition of 15% or 25% EG to
the composite instead of APP, however, resulted in enhanced char formation
in the first-step decomposition but little change in the decomposition
temperature. The temperature of the second-step decomposition was
increased (5–98C) as a result of the thermal insulation properties of the
expanded graphite. In cone calorimeter testing, they showed that both APP
and EG as additives reduced the PHRR and THR; however, APP also
resulted in an increase in smoke and carbon monoxide production per unit
mass loss. They concluded that EG reduced both fire risk and fire hazard,
whereas APP reduced fire risk but increased fire hazard.
ALUMINIUM TRIHYDRATE
Aluminium trihydrate (ATH), 2Al(OH)3, is an active filler for reducing
the flammability of composites [18,20]. It is an effective, low-cost flame
retardant and is widely used even though a high loading (450% for
some polymers) and is often required to achieve adequate flame retardancy.
ATH starts decomposing at around 2208C, so composite processing
temperatures should be below 2008C. ATH decomposes by the endothermic
reaction as follows:
The main endothermic peak occurs at about 3008C, which means that it is
absorbing heat from the polymer at a temperature below that at which most
composite polymers degrade. The water released during decomposition
restricts oxygen access to the composite surface and dilutes the concentration
of flammable gases evolved. It is thought that it may promote char formation
in some polymers by a condensation phase mechanism. In their study on an
MAGNESIUM HYDROXIDE
Another endothermic flame retardant is magnesium hydroxide [20],
Mg(OH)2, which decomposes by the endothermic reaction as follows:
MgðOHÞ2 ! MgO þ H2 O
OTHER ADDITIVES
Other strategies regarding the addition of flame retardants could include
the addition of catalysts or nanocatalysts [40]. According to Lewin [40], it is
thought that no chemical interaction takes place between endothermic fire
retardants, such as magnesium hydroxide and ATH, and the polymer during
pyrolysis and combustion. However, in the presence of a catalyst such as
manganese borate, ferrocene, and nickel II oxide, it was found that chemical
interactions occurred between the fire retardant and the polymer, which
resulted in increased char and oxygen index.
INTUMESCENT SYSTEMS
Intumescents can be used as additives for thermoplastic and thermoset
resins, acting as char promoters [20,47]. An intumescent system is illustrated
in Figure 2.
The system consists of a dehydrating agent that releases acid during
thermal decomposition, a carbonizing substance, containing a large number
of carbon and hydroxyl groups, which undergoes esterification with the acid
and later decomposes to form carbon, acid, water, and CO2, and a foam
producing substance, which evolves large quantities of nonflammable gases.
An intumescent char is then formed from the decomposition products of the
carbonizing agent and the nonflammable gases [20,47,68]. The char forms an
insulating layer that retards heat transfer and retards oxygen access. Le Bras
et al. [69] studied the effect of an intumescent system, comprising APP,
pentaerythritol, and melamine, in a polypropylene/flax composite. In UL-94
testing [70], they found that virgin polypropylene and a polypropylene
composite burnt completely and had a no classification (NC) rating. A
polypropylene/flax/APP composite formed a carbonaceous char but still
had a NC rating, whereas the polypropylene/flax composite with the
intumescent system formed a stable intumescent char and achieved a V-0
rating. They showed that an optimized flame-retardant formulation could
be obtained by the association of a char-forming cellulose material with an
intumescent char structure.
Intumescent char
(50 – 200 times original size)
Figure 2. Intumescent system (redrawn from Mouritz and Gibson [20] and Kandola and
Nazare [47]).
RESIN BLENDS
Kandola et al. [47] reported on the use of resin blends to improve flame
retardancy. This involves blending of polymers with poor flame retardancy
with polymers having good flame retardancy. For example, Chiu et al. [71]
studied the thermal degradation and combustion properties of an
unsaturated polyester resin blended with a phenolic resin. The blended
resin showed improved heat resistance and a reduction in heat release and
smoke and toxic gas emissions.
NANOCOMPOSITES
Another option is the incorporation of nanoparticles such as clays,
organically modified clays, or low melting glasses [15,18,40,47,72,73].
The clays are not flame retardant in themselves; however, their introduction
into a polymer can reduce PHRR, although THR remains the same. There are
several mechanisms in play, and they impact on different fire properties. It is
proposed that as the polymer is exposed to heat, platelets migrate to the
surface providing a protective layer that delays gasification of the surface
below the layer. The clays also assist in formation of a carbonaceous-silicate
char, which acts as a heat barrier, increasing thermal stability, and a physical
barrier to mass transport. The nanoparticles can also reduce the melt flow of
the polymer, and the change in melt viscosity and barrier formation results in
reduced flame spread. Nanoparticles can be used in combination with other
flame retardants. There is a synergistic effect, which gives improved flame
retardancy and would allow for a reduction in the amount of flame retardant
used. Kozlowski et al. [74] reported on the flammability of poly(lactic acid)/
organically modified montmorillonite nanocomposites. In UL-94 horizontal
burn testing, they found that the clays decreased the rate of burning. Marosfoi
et al. [75] examined the combustion properties of sepiolite, an organically
treated sepiolite, both needle-like clays, and montmorillonite, a layered clay,
in combination with magnesium hydroxide in a polypropylene matrix. They
found that the PHRR and TTI of the organically modified clay/magnesium
hydroxide combination were lower than when either of the additives was
used alone. For example, the PHRR of polypropylene with 10% magnesium
hydroxide was 471 kW/m2 and that of polypropylene containing 10%
magnesium, hydroxide, and 5% organically modified sepiolite was 328 kW/
m2. They proposed that the clay had a catalytic effect in promoting charring
and a micromechanical effect, acting as a fibrous reinforcement, which
improved the mechanical properties of the char. Combination of sepiolite and
montmorillonite clays with the flame retardant resulted in increased TTI and
decreased HRR when compared to the flame retardant on its own. They
concluded that the two types of clay worked synergistically with the flame
retardant and a further advantage could be gained by combining the two.
Reinforcing Fibers
DIAMMONIUM PHOSPHATE
Diammonium phosphate (DAP), (NH4)2HPO4, is a condensed phase
flame retardant that has been used for a long time as a nondurable flame
retardant for cellulosic textiles [32,44,76,77]. DAP decomposes at around
1558C, well below the decomposition temperature of cellulose, forming
phosphoric acid and ammonia. The phosphoric acid formed can phosphor-
ylate the primary hydroxyl group of cellulose to form a phosphorous
ester. These esters catalyze the dehydration of cellulose, promoting the
formation of char and water at the expense of levoglucosan. The acid
may also cross-link with the cellulose changing the normal pathway
of pyrolysis to yield less flammable products. Matkó et al. [13] investigated
the flame retardancy of polyurethane/cellulosic composites using DAP
as a flame retardant for the cellulosic component. A polyurethane/wood
flake composite had a LOI value of 23% and a polyurethane/corn
shell composite had a LOI value of 20%. When DAP was used as the
flame-retarding agent, the composites had LOI values of 30% and 29%,
respectively. UL 94 ratings improved from H-B (no flame retardant) to V-0
(DAP). They found little difference in the level of flame retardancy
when using as an additive in the resin instead of treatment of the cellulosic
with DAP.
FIBER MODIFICATION
The usefulness of acetylation of sisal in improving thermal stability has
already been mentioned [48]. Thermal stability can also be improved by
grafting. Sabaa [84] reported that the grafting of acrylonitrile on sisal fibers
improved thermal stability, as indicated by reduced weight loss and rate of
degradation and an increased initial degradation temperature. An increased
degradation temperature from 1708C to 2808C for jute grafted with
acrylonitrile was reported by Mohanty et al. [85].
Novel fiber modifications to improve fire resistance include a keratin-
cellulose filament, produced from wool fiber wastes and cellulose acetate.
The filament, with improved fire resistance, was reported by Aluigi et al. [86].
White et al. [87] reported on a spun fiber that contained 93% cotton and 7%
clay. The composite fiber was found to have a heat tolerance of 30–358C
greater than that of either cotton or regenerated cellulose fibers. The fibers
formed a char outer layer when heated.
COMPOSITES
The fire resistance of the composite can be improved by applying a fire
retardant or thermal barrier coating [18,20,47]. Commonly, these are only
applied to thermoset composites such as those based on epoxy, polyester,
and vinyl ester resins and challenges exist for their use on thermoplastic-
based composites. A coating has the advantage that it does not modify the
intrinsic properties of the composite. The coating can be in the form of an
organic polymer such as a phenolic or alkyd resin, with or without a flame-
retardant filler. These coatings delay ignition and prevent flame spread and
heat penetration. They are generally low cost and effective, but there is a
limit to the thickness that can be applied and hence the level of protection
obtained. Inorganic polymers such as geopolymers and polyhedral
oligomeric silsesquioxanes can also be used. They provide a better level of
protection compared to organic polymers because of their greater resistance
to pyrolysis and heat conduction.
SUMMARY
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