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Why Mattress Fire Testing is
50% Science and 50% Art
Brent L. Larson, Project Manager
Element Materials Technology, St. Paul, MN




 April 25, 2012      www.element.com
Things To Keep In Mind
•    If you are disconnected during the presentation
     • You should be able to log right back in.

•    Questions
     • The system is set up for you to text questions at anytime during the presentation,
     but they will not be addressed until the end (to better maintain continuity).

4.   Copies of the presentation
     • A recording will be made of the presentation and made available on our website in
     the near future at: www.element.com. You will be notified by email when it is available
     for viewing.




                                              Mattress Fire Testing                         2
Overview
1. Review of Test Procedures (presented in historical order)
    •   CPSC CFR 1632 - 1973
    •   CA TB 121 - 1980
    •   CA TB 129 - 1992
    •   BOSTON IX-11 - 1993
    •   CPSC CFR 1633 - 2007
2. To Test or Not to Test, That is the Question!
3. Wrap Up
4. Questions From Attendees




                                     Mattress Fire Testing     3
CPSC CFR 1632 Cigarette Test
•   “STANDARD FOR THE FLAMMABILITY OF MATTRESSES AND
    MATTRESS PADS (FF 4–72, AMENDED)”

•   Application: to determine the ignition resistance of a mattress or a
    mattress pad when exposed to a lighted cigarette (prior to being
    introduced into commerce)
     – Ticking materials substitution test
     – Tape edge materials substitution test

•   Ignition Source: non-filtered cigarettes (currently NIST 1196)




                                      Mattress Fire Testing                4
CPSC CFR 1632 (Mattress/Mattress Pad Test)




                        Mattress Fire Testing   5
CPSC CFR 1632 (Mattress/Mattress Pad Test)
Pass/Fail Criteria

•   Char cannot exceed 2 inches in any direction (including down into the
    mattress) from the nearest edge of the cigarette

•   Obvious ignition




                                     Mattress Fire Testing                  6
CPSC CFR 1632 (Ticking Substitution Test)




                         Mattress Fire Testing   7
CPSC CFR 1632 (Ticking Substitution Test)
Pass/Fail Criteria

•   Char cannot exceed 1 inch in any direction from the nearest edge of
    the cigarette

•   Cotton felt is not ignited

•   If a tick or quilted tick passes while tested directly over the cotton felt, it
    is a “class A” tick (meaning it is resistant to combustion)

•   If a tick/quilted tick fails directly over the cotton felt, but passes when
    re-tested with the ¼” polyfoam in place, it is a “class B” tick (meaning it
    is neutral to combustion)


                                         Mattress Fire Testing                    8
CPSC CFR 1632 (Tape Edge Substitution Test)




                        Mattress Fire Testing   9
CPSC CFR 1632 (Tape Edge Substitution Test)
Pass/Fail Criteria

•   Char cannot exceed 2 inches in any direction (including down into the
    mattress) from the nearest edge of the cigarette

•   Obvious ignition




                                     Mattress Fire Testing                  10
California TB 121
•   “Flammability Test Procedure for Mattresses For Use In High Risk
    Occupancies”

•   Application: HIGH RISK occupancies-might include, but are not limited
    to, jails, prisons, penal institutions, correctional facilities, juvenile
    detention centers, nursing homes, and health care facilities.

•   Ignition Source: Wadded Newspaper

•   Non-calorimetry test




                                      Mattress Fire Testing                 11
California TB 121




                    Mattress Fire Testing   12
California TB 121
Pass/Fail Criteria

•   Greater than 10% mass loss in the 1st 10 minutes

•   Temperature 1 inch below the ceiling of 500 ºF or greater

•   Carbon monoxide level exceeds 1,000 ppm

Note: no heat release criteria




                                     Mattress Fire Testing      13
California TB 129
•   “Flammability Test Procedure For Mattresses For Use In Public
    Buildings”

•   Application: health care facilities, retirement, convalescent and board
    and care homes, college dormitories and residence halls

•   Ignition source: propane burner (with dual jets)
     – Application time: 3 minutes




                                      Mattress Fire Testing                   14
California TB 129 (setup with foundation)




                          Mattress Fire Testing   15
California TB 129 (setup without foundation)




                          Mattress Fire Testing   16
California TB 129
Pass/Fail Criteria

•   Peak rate of heat release of less than 100 kW in 60 minutes

•   Total heat released at 10 minutes less than 25 MJ

•   Mass loss due to combustion at 10 minutes less than 3 lbs




                                     Mattress Fire Testing        17
Boston Fire Department
•   Boston IX-11 Mattress Fire Test

•   Application: health care facilities, hotels and dormitories

•   Ignition Source: “bed clothing” (sheets, blanket and pillow)
     – Bed cloths are initially ignited by use of a hand held butane lighter




                                          Mattress Fire Testing                18
Boston Fire Department




                    Mattress Fire Testing   19
Boston Fire Department
Pass/Fail Criteria

•   Peak rate of heat release of less than or equal to 150 kW in 30 minutes

•   Total heat released at 10 minutes less than or equal to 30 MJ

•   Mass loss due to combustion must be less than or equal to the weight
    of the bed cloths

•   NOTE: the above published criteria not withstanding, the Boston Fire
    Department reserves the sole right to declare if a mattress design has
    passed the test



                                     Mattress Fire Testing                   20
CPSC CFR 1633 Open Flame Test
•   Standard for the Flammability (Open Flame) of Mattress Sets; Final
    Rule

•   Application: The requirements of this part 1633 shall apply to each
    ‘‘manufacturer’’ of mattress sets which are manufactured for sale in
    commerce.

•   Ignition Source: dual propane burners (top and side of mattress or
    mattress set)
     – Application time:
         • 70 seconds for top burner
         • 50 seconds for side burner




                                        Mattress Fire Testing              21
CPSC CFR 1633 Open Flame Test




                  Mattress Fire Testing   22
CPSC CFR 1633 Open Flame Test




                  Mattress Fire Testing   23
CPSC CFR 1633 Open Flame Test
Pass/Fail Criteria

•   Peak rate of heat release of less or equal to 200 kW in 30 minutes

•   Total heat released at 10 minutes less than or equal to 15 MJ

•   3 consecutive mattresses (and/or mattress sets) must pass the above
    criteria to qualify a prototype design

•   1 mattress (and/or mattress set) must pass the above criteria for a
    “confirmation” test




                                     Mattress Fire Testing                24
Now What ??




     Mattress Fire Testing   25
Are All of These Tests Required
(or even necessary)?


• The short answers are: YES and TBD




                           Mattress Fire Testing   26
Minimum Requirements to Sell in the US

•   Most mattresses sold on the open US market will require 1632/1633
    testing
    – 1632/1633: two sides of the same coin


•   NOT with the scope of 1632/1633
    – Motor Vehicles
    – Boats
    – Medical Devices


•   “One of a Kind” mattresses may be exempted




                                      Mattress Fire Testing             27
Minimum Requirements to Sell in the US

•   Will the 1632 cigarette test be phased out?

•   Not likely anytime soon.
     – WHY?
         • lack of data




                                     Mattress Fire Testing   28
Minimum Requirements to Sell in California

•   CPSC 1632/1633



•   Additionally: California TB 129 if the mattresses are intended for public
    occupancy (hotels, dormitories, etc.)




                                      Mattress Fire Testing                 29
1633 / TB 129 Comparison

                            TEST               1633                   TB 129
      Pass/Fail - Peak Rate of Heat
                                              200 kW                  100 kW
                          Release:

    Pass/Fail - Total Heat @ 10 min:           15 MJ                   25 MJ

              Pass/Fail: Mass Loss:              n/a                    3 lbs

                                       propane burners             propane burner
                    Ignition Source:
                                          top & side           (side of bed, dual jets)

                   Application Time:     70 sec/50 sec               3 minutes

                      Test Duration:       30 minutes                60 minutes




                                       Mattress Fire Testing                              30
Minimum Requirements to Sell in Boston, MA


•   CPSC 1632/1633



•   Additionally: Boston IX-11 if the mattresses are intended for public
    occupancy (hotels, dormitories, etc.)




                                      Mattress Fire Testing                31
1633 / Boston IX-11 Comparison

                               TEST               1633              Boston IX-11
         Pass/Fail - Peak Rate of Heat
                                                 200 kW                 150 kW*
                             Release:

       Pass/Fail - Total Heat @ 10 min:           15 MJ                 30 MJ*

                 Pass/Fail: Mass Loss:              n/a           weight of bed cloths*

                                                                       bed cloths
                                          propane burners
                       Ignition Source:                             (sheets, blanket,
                                             top & side
                                                                         pillow)

                      Application Time:     70 sec/50 sec                 n/a

                         Test Duration:       30 minutes              30 minutes

   *Pass/Fail ultimately determined by the Boston Fire Department

                                          Mattress Fire Testing                           32
Wrap Up: Common Questions



•   Does passing one of these tests gauge performance to any of the
    others?




                                    Mattress Fire Testing             33
Wrap Up: Common Questions
                                                                               Boston
                         TEST        TB 121             TB 129                                     1633
                                                                                IX-11
    Pass/Fail - Peak Rate of Heat
                                         n/a              100 kW                150 kW*             200 kW
                        Release:

  Pass/Fail - Total Heat @ 10 min:       n/a               25 MJ                30 MJ*              15 MJ

                                     Over 10%                                weight of bed
            Pass/Fail: Mass Loss:                     3 lbs @ 10 min                                  n/a
                                     @ 10 min                                   cloths*

                                                      propane burner           bed cloths
                                      Wadded                                                    propane burners
                  Ignition Source:                   (side of bed, dual     (sheets, blanket,
                                     newspaper                                                     top & side
                                                            jets)                pillow)

                 Application Time:       n/a             3 minutes                n/a            70 sec/50 sec


                    Test Duration:   60 minutes**       60 minutes            30 minutes          30 minutes



*Pass/Fail ultimately determined by the Boston Fire Department
** time limit not specifically listed in TB 121

                                                    Mattress Fire Testing                                      34
Wrap Up: Common Questions


•   Do I need to retest if I am considering a component change?
    – It depends
        • Is there reason to believe the overall FR performance of the mattress could be
          altered?
        • How much testing have you conducted previously?
        • Is the new component fairly similar to an existing material?
        • What is an “objectively reasonable basis”??




                                                                                           35
Wrap Up: Common Questions



•   Is there a component level test that will help predict full scale test
    results?
     – To date there is not (at least in a public forum).
     – That said, component testing can still be of value for quality assurance
       applications.




                                                                                  36
Wrap Up: Common Questions



•   Can we as an independent lab offer design recommendations?
    – Conflict of interest
    – We can offer assistance with the basics of a testing program, but not
      specific product design




                                                                              37
To Get More Information

• MY CONTACT INFO
  Phone: 651 659 7218
  Cell: 651 248 8847
  Email: brent.larson@element.com
  Website: www.element.com
  Connect to me on LinkedIn
      • I will soon be starting a blog to continue the discussion




                                          Mattress Fire Testing     38

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Why Mattress Fire Testing is 50% Science and 50% Art

  • 1. Why Mattress Fire Testing is 50% Science and 50% Art Brent L. Larson, Project Manager Element Materials Technology, St. Paul, MN April 25, 2012 www.element.com
  • 2. Things To Keep In Mind • If you are disconnected during the presentation • You should be able to log right back in. • Questions • The system is set up for you to text questions at anytime during the presentation, but they will not be addressed until the end (to better maintain continuity). 4. Copies of the presentation • A recording will be made of the presentation and made available on our website in the near future at: www.element.com. You will be notified by email when it is available for viewing. Mattress Fire Testing 2
  • 3. Overview 1. Review of Test Procedures (presented in historical order) • CPSC CFR 1632 - 1973 • CA TB 121 - 1980 • CA TB 129 - 1992 • BOSTON IX-11 - 1993 • CPSC CFR 1633 - 2007 2. To Test or Not to Test, That is the Question! 3. Wrap Up 4. Questions From Attendees Mattress Fire Testing 3
  • 4. CPSC CFR 1632 Cigarette Test • “STANDARD FOR THE FLAMMABILITY OF MATTRESSES AND MATTRESS PADS (FF 4–72, AMENDED)” • Application: to determine the ignition resistance of a mattress or a mattress pad when exposed to a lighted cigarette (prior to being introduced into commerce) – Ticking materials substitution test – Tape edge materials substitution test • Ignition Source: non-filtered cigarettes (currently NIST 1196) Mattress Fire Testing 4
  • 5. CPSC CFR 1632 (Mattress/Mattress Pad Test) Mattress Fire Testing 5
  • 6. CPSC CFR 1632 (Mattress/Mattress Pad Test) Pass/Fail Criteria • Char cannot exceed 2 inches in any direction (including down into the mattress) from the nearest edge of the cigarette • Obvious ignition Mattress Fire Testing 6
  • 7. CPSC CFR 1632 (Ticking Substitution Test) Mattress Fire Testing 7
  • 8. CPSC CFR 1632 (Ticking Substitution Test) Pass/Fail Criteria • Char cannot exceed 1 inch in any direction from the nearest edge of the cigarette • Cotton felt is not ignited • If a tick or quilted tick passes while tested directly over the cotton felt, it is a “class A” tick (meaning it is resistant to combustion) • If a tick/quilted tick fails directly over the cotton felt, but passes when re-tested with the ¼” polyfoam in place, it is a “class B” tick (meaning it is neutral to combustion) Mattress Fire Testing 8
  • 9. CPSC CFR 1632 (Tape Edge Substitution Test) Mattress Fire Testing 9
  • 10. CPSC CFR 1632 (Tape Edge Substitution Test) Pass/Fail Criteria • Char cannot exceed 2 inches in any direction (including down into the mattress) from the nearest edge of the cigarette • Obvious ignition Mattress Fire Testing 10
  • 11. California TB 121 • “Flammability Test Procedure for Mattresses For Use In High Risk Occupancies” • Application: HIGH RISK occupancies-might include, but are not limited to, jails, prisons, penal institutions, correctional facilities, juvenile detention centers, nursing homes, and health care facilities. • Ignition Source: Wadded Newspaper • Non-calorimetry test Mattress Fire Testing 11
  • 12. California TB 121 Mattress Fire Testing 12
  • 13. California TB 121 Pass/Fail Criteria • Greater than 10% mass loss in the 1st 10 minutes • Temperature 1 inch below the ceiling of 500 ºF or greater • Carbon monoxide level exceeds 1,000 ppm Note: no heat release criteria Mattress Fire Testing 13
  • 14. California TB 129 • “Flammability Test Procedure For Mattresses For Use In Public Buildings” • Application: health care facilities, retirement, convalescent and board and care homes, college dormitories and residence halls • Ignition source: propane burner (with dual jets) – Application time: 3 minutes Mattress Fire Testing 14
  • 15. California TB 129 (setup with foundation) Mattress Fire Testing 15
  • 16. California TB 129 (setup without foundation) Mattress Fire Testing 16
  • 17. California TB 129 Pass/Fail Criteria • Peak rate of heat release of less than 100 kW in 60 minutes • Total heat released at 10 minutes less than 25 MJ • Mass loss due to combustion at 10 minutes less than 3 lbs Mattress Fire Testing 17
  • 18. Boston Fire Department • Boston IX-11 Mattress Fire Test • Application: health care facilities, hotels and dormitories • Ignition Source: “bed clothing” (sheets, blanket and pillow) – Bed cloths are initially ignited by use of a hand held butane lighter Mattress Fire Testing 18
  • 19. Boston Fire Department Mattress Fire Testing 19
  • 20. Boston Fire Department Pass/Fail Criteria • Peak rate of heat release of less than or equal to 150 kW in 30 minutes • Total heat released at 10 minutes less than or equal to 30 MJ • Mass loss due to combustion must be less than or equal to the weight of the bed cloths • NOTE: the above published criteria not withstanding, the Boston Fire Department reserves the sole right to declare if a mattress design has passed the test Mattress Fire Testing 20
  • 21. CPSC CFR 1633 Open Flame Test • Standard for the Flammability (Open Flame) of Mattress Sets; Final Rule • Application: The requirements of this part 1633 shall apply to each ‘‘manufacturer’’ of mattress sets which are manufactured for sale in commerce. • Ignition Source: dual propane burners (top and side of mattress or mattress set) – Application time: • 70 seconds for top burner • 50 seconds for side burner Mattress Fire Testing 21
  • 22. CPSC CFR 1633 Open Flame Test Mattress Fire Testing 22
  • 23. CPSC CFR 1633 Open Flame Test Mattress Fire Testing 23
  • 24. CPSC CFR 1633 Open Flame Test Pass/Fail Criteria • Peak rate of heat release of less or equal to 200 kW in 30 minutes • Total heat released at 10 minutes less than or equal to 15 MJ • 3 consecutive mattresses (and/or mattress sets) must pass the above criteria to qualify a prototype design • 1 mattress (and/or mattress set) must pass the above criteria for a “confirmation” test Mattress Fire Testing 24
  • 25. Now What ?? Mattress Fire Testing 25
  • 26. Are All of These Tests Required (or even necessary)? • The short answers are: YES and TBD Mattress Fire Testing 26
  • 27. Minimum Requirements to Sell in the US • Most mattresses sold on the open US market will require 1632/1633 testing – 1632/1633: two sides of the same coin • NOT with the scope of 1632/1633 – Motor Vehicles – Boats – Medical Devices • “One of a Kind” mattresses may be exempted Mattress Fire Testing 27
  • 28. Minimum Requirements to Sell in the US • Will the 1632 cigarette test be phased out? • Not likely anytime soon. – WHY? • lack of data Mattress Fire Testing 28
  • 29. Minimum Requirements to Sell in California • CPSC 1632/1633 • Additionally: California TB 129 if the mattresses are intended for public occupancy (hotels, dormitories, etc.) Mattress Fire Testing 29
  • 30. 1633 / TB 129 Comparison TEST 1633 TB 129 Pass/Fail - Peak Rate of Heat 200 kW 100 kW Release: Pass/Fail - Total Heat @ 10 min: 15 MJ 25 MJ Pass/Fail: Mass Loss: n/a 3 lbs propane burners propane burner Ignition Source: top & side (side of bed, dual jets) Application Time: 70 sec/50 sec 3 minutes Test Duration: 30 minutes 60 minutes Mattress Fire Testing 30
  • 31. Minimum Requirements to Sell in Boston, MA • CPSC 1632/1633 • Additionally: Boston IX-11 if the mattresses are intended for public occupancy (hotels, dormitories, etc.) Mattress Fire Testing 31
  • 32. 1633 / Boston IX-11 Comparison TEST 1633 Boston IX-11 Pass/Fail - Peak Rate of Heat 200 kW 150 kW* Release: Pass/Fail - Total Heat @ 10 min: 15 MJ 30 MJ* Pass/Fail: Mass Loss: n/a weight of bed cloths* bed cloths propane burners Ignition Source: (sheets, blanket, top & side pillow) Application Time: 70 sec/50 sec n/a Test Duration: 30 minutes 30 minutes *Pass/Fail ultimately determined by the Boston Fire Department Mattress Fire Testing 32
  • 33. Wrap Up: Common Questions • Does passing one of these tests gauge performance to any of the others? Mattress Fire Testing 33
  • 34. Wrap Up: Common Questions Boston TEST TB 121 TB 129 1633 IX-11 Pass/Fail - Peak Rate of Heat n/a 100 kW 150 kW* 200 kW Release: Pass/Fail - Total Heat @ 10 min: n/a 25 MJ 30 MJ* 15 MJ Over 10% weight of bed Pass/Fail: Mass Loss: 3 lbs @ 10 min n/a @ 10 min cloths* propane burner bed cloths Wadded propane burners Ignition Source: (side of bed, dual (sheets, blanket, newspaper top & side jets) pillow) Application Time: n/a 3 minutes n/a 70 sec/50 sec Test Duration: 60 minutes** 60 minutes 30 minutes 30 minutes *Pass/Fail ultimately determined by the Boston Fire Department ** time limit not specifically listed in TB 121 Mattress Fire Testing 34
  • 35. Wrap Up: Common Questions • Do I need to retest if I am considering a component change? – It depends • Is there reason to believe the overall FR performance of the mattress could be altered? • How much testing have you conducted previously? • Is the new component fairly similar to an existing material? • What is an “objectively reasonable basis”?? 35
  • 36. Wrap Up: Common Questions • Is there a component level test that will help predict full scale test results? – To date there is not (at least in a public forum). – That said, component testing can still be of value for quality assurance applications. 36
  • 37. Wrap Up: Common Questions • Can we as an independent lab offer design recommendations? – Conflict of interest – We can offer assistance with the basics of a testing program, but not specific product design 37
  • 38. To Get More Information • MY CONTACT INFO Phone: 651 659 7218 Cell: 651 248 8847 Email: brent.larson@element.com Website: www.element.com Connect to me on LinkedIn • I will soon be starting a blog to continue the discussion Mattress Fire Testing 38