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Flammability, Smoke Generation,
and Toxicity
| The flammability and smoke generation criteria in this section
are based upon industry standards, NFPA 130 - Standard for Fixed Guideway
Transit and Passenger Rail Systems, and 49 CFR Appendix B To Part 238-Test
Methods And Performance Criteria For The Flammability And Smoke Emission
Characteristics Of Materials Used In Passenger Cars And Locomotive Cabs,
which are very similar, but not exactly the same. The comments and table
provided are a combination of both NFPA 130/49 CFR tables, and common
usage in passenger rail applications. The criteria provided below is
more restrictive (slightly) than the original NFPA 130/49 CFR requirements.
Several criteria have been further restricted to preclude the use of
several poor performing materials that are frequently proposed. In general,
these precluded materials will barely meet the NFPA 130 criteria when
prepared as samples, but frequently fail the NFPA 130 criteria in a
production environment.
The following toxic gas generation table is also based upon common usage in the passenger
rail industry. In recent years, data has been required for heat release
rate and combustible load although acceptance criteria varies.
It is also common in properties that operate in restrictive environments
such as tunnels, bridges, or elevated structures, to further impose
combustible content criteria such as heat release rate (kW, BTU/hr),
and total combustible content (kJ/kg, BTU/lb). This data is commonly
obtained with ASTM E1354 |
| Standard: |
ASTM E162 - Standard Test
Method for Surface Flammability of Materials Using a Radiant Heat
Energy Source
| | Purpose: |
ASTM E162 is used to test the flame spread rate when the material
is exposed to a specified heat source. This test is applicable to
sheet products or products that can be formed into a sheet that
are normally exposed to the environment. For cellular materials,
use ASTM D3675.
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| Criteria: |
Specify standard name, Index variable (Is) associated
with a less than or equal to value to obtain full criteria. |
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| Usage: |
ASTM E162, Is ≤ X (Value) - Please see table below
for typical values
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| Standard: |
ASTM E662 - Standard Test
Method for Specific Optical Density of Smoke Generated by Solid
Materials
| | Purpose: |
ASTM E662 is used to test the optical density of the smoke evolved
from a material when it is exposed to a specified heat source. This
test is applicable to sheet products or products that can be formed
into a sheet that are normally exposed to the environment.
Note: this test may be run simultaneously with BSS-7239, and/or
ASTM E1354
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| Criteria: |
Specify standard name, Index variable (Ds), at a specific time
duration and a less than or equal to value, to obtain full criteria.
Typical times for this are Ds (1.5) - 1 1/2 minutes and Ds (4.0)
- 4 minutes
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| Usage: |
ASTM E662, Ds(1.5) ≤ X (Value) - Please see table below
for typical values
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| Standard: |
ASTM C542 - Standard Specification
for Lock-Strip Gaskets
| | Purpose: |
ASTM C542 is used to define the required properties of lock-strip
gaskets where resistance to sunlight, weathering, flame, oxidation,
permanent deformation under load, and diminution of gripping pressure
are prime essentials. This standard is frequently confused for a
flammability requirement since it has been typically cited in the
flammability portion of many specifications. This standard calls
ASTM C1166 for the flammability portion of this standard.
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| Criteria: |
Specify standard name, "Pass" - (this is a pass/fail specification
containing multiple criteria)
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| Usage: |
ASTM C542, Pass
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| Standard: |
ASTM C1166 - Standard Test
Method for Flame Propagation of Dense and Cellular Elastomeric Gaskets
and Accessories
| | Purpose: |
ASTM C1166 is used to test the flame spread rate when the material
is exposed to a specified heat source. This test is applicable to
non-sheet products such as gaskets, weatherstrip, or packing products
that can not be formed into a sheet. These materials are commonly
not exposed to the environment.
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| Criteria: |
Specify standard name, and maximum flame propagation length.
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| Usage: |
ASTM C1166, X (length) maximum flame propagation - Please see
table below for typical values
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| Standard: |
ASTM D3675 - Standard Test
Method for Surface Flammability of Flexible Cellular Materials Using
A Radiant Heat Energy Source
| | Purpose: |
ASTM D3675 covers the measurement of surface flammability of
flexible cellular materials. This test method is similar to ASTM
E162 but has been modified to use on flexible cellular materials
such as foams, or cellular neoprene.
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| Criteria: |
Specify standard name, Index variable (Is) associated with a
less than or equal to value to obtain full criteria
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| Usage: |
ASTM D3675, Is ≤ X (Value) - Please see table below
for typical values
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| Standard: |
ASTM E119 - Standard Test
Methods for Fire Tests of Building Construction and Materials
| | Purpose: |
The test methods described in this fire-test-response standard
are applicable to assemblies of masonry units and to composite assemblies
of structural materials for buildings, including bearing and other
walls and partitions, columns, girders, beams, slabs, and composite
slab and beam assemblies for floors and roofs. They are used in
passenger transit rail vehicles to provide floor and roof fire resistance
criteria.
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| Criteria: |
Specify standard name, and minimum fire resistance duration,
added criteria (if any)
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| Usage: |
ASTM E119, Pass - 30 Minutes minimum endurance at AW3 loading.
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| Standard: |
ASTM E648 - Standard Test
Method for Critical Radiant Flux of Floor-Covering Systems Using
a Radiant Heat Energy Source
| | Purpose: |
This fire-test-response standard covers a procedure for measuring
the critical radiant flux of horizontally mounted floor-covering
systems exposed to a flaming ignition source in a graded radiant
heat energy environment in a test chamber. A specimen is mounted
over underlayment, a simulated concrete structural floor, bonded
to a simulated structural floor, or otherwise mounted in a typical
and representative way.
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| Criteria: |
Specify standard name, and radiant flux threshold
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| Usage: |
ASTM E648, CRF ³ 0.5 W/cm2
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| Standard: |
ASTM E1354 - Standard Test
Method for Heat and Visible Smoke Release Rates for Materials and
Products Using an Oxygen Consumption Calorimeter
| | Purpose: |
ASTM E1354 test method is used to determine the ignitability,
heat release rates, mass loss rates, effective heat of combustion,
and visible smoke development of materials and products.
Note: this test may be run simultaneously with BSS-7239, and/or
ASTM E662.
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| Criteria: |
Specify standard name, and maximum values for each of the desired
values
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| Usage: |
ASTM E1354, heat release rate≤ X (Value), effective heat of combustion≤ X (Value), etc.
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| Standard: |
BSS-7239 - Test Method for
Toxic Gas Generation From Materials on Combustion
| | Purpose: |
BSS-7239 is used to measure the toxic gas generation is combustion
products. This test is usually run in conjunction with ASTM E662
or ASTM E1354
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| Criteria: |
Specify standard name, and maximum values for each of the desired
values
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| Usage: |
BSS-7239, Maximum values - Please see table below for typical values
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Materials used in the vehicle shall comply with the flammability;
smoke emission, toxic gas, and fire retardation requirements specified
herein.
Materials used in the vehicles shall be low halogen in
addition to meeting the low-smoke requirements specified below.
As a minimum, all materials used in the construction of
the vehicle shall meet the requirements of the 49 CFR 238.103, and Appendix
B to Part 238-Test Methods and Performance Criteria for the Flammability
and Smoke Emission Characteristics of Materials Used in Passenger Cars
and Locomotive Cabs. Unless otherwise specified below, all materials
and construction shall meet the requirements of NFPA 130 - 2003, Table
8.4, shall be enforced.
Should a conflict exist between the NFPA and Federal
requirements and requirements listed elsewhere in these provisions,
the more restrictive will govern.
The Contractor should furnish a list of materials
(flammability matrix) used in the vehicles showing location of
material, weight (density and total weight), heat value per pound
and per vehicle, flame spread, flashpoint, smoke generation, and
toxicity. The Contractor should submit laboratory test results
for each test, including a technical data sheet, for approval.
This is normally a contract deliverable requirement "[CDRL]"
Test report documentation shall specifically identify
the tested material by the same description that appears on the technical
data sheet and other related references. This documentation must be
directly traceable to the applicable carbuilder drawings without ambiguity.
Copies of prior test results showing that proposed materials
have complied with the specified standards and tests may be submitted
for approval. Assurance may be required that the material presently
being considered for use is the same composition as that previously
tested.
Flammability And Smoke Generation Criteria
| Function of Material (see
comments) |
Test Procedure |
Performance Criteria |
| All vehicle materials & components except as otherwise
noted.
(Wall Panels, Ceiling Panels, Partition Panels, Windscreens,
Fiberglass, Plastics, Diaphragms, Non-sealing Elastomers,
etc.) (1, 2, 9, 12) |
ASTM E 162
ASTM E 662 |
Is < 35
Ds (1.5) < 100,
Ds (4.0) < 200
(to exclude polyester resin FRP, use the following: Ds
(1.5) < 100, Ds
(4.0) < 165) |
| HVAC Ducting
(1, 2) |
ASTM E 162
ASTM E 662 |
Is < 35
Ds (4.0) < 100 |
| Lighting Diffusers / Plastic Glazing
(2, 14) |
ASTM E 162
ASTM E 662 |
Is < 100
Ds (1.5) < 100,
Ds (4.0) < 200 |
| Thermal and Acoustical Insulation
(1, 2) |
ASTM E 162
ASTM E 662 |
Is < 25
Ds (4.0) < 100 |
| Flexible Cellular Foams
(1, 2, 4, 6) |
ASTM D 3675
ASTM E 662 |
Is < 25
Ds (1.5) < 100,
Ds (4.0) < 175 |
| Elastomers – Lock strip gaskets
(1, 2, 10, 11) |
ASTM C 542
ASTM E 662 |
Pass criteria in table 1
Ds (1.5) < 100,
Ds (4.0) < 200 |
| Elastomers – Other gaskets or seals
(1, 2, 10, 11) |
ASTM C 1166
ASTM E 662 |
100mm (4.0in), maximum flame propagation (15)
Ds (1.5) < 100,
Ds (4.0) < 200 |
| Structural – Floor, Roof
(16, 17, 18) |
ASTM E 119 |
Pass (30 Minutes minimum endurance at AW3 loading) |
| Floor Covering
(12, 13) |
ASTM E 648
ASTM E 662 |
CRF > 0.5 W/cm2
(5kW/m2)
Ds (1.5) < 100,
Ds (4.0) < 200 |
| Seat Cushion, Mattresses
(1, 2, 3, 4, 5, 6, 7, 8) |
ASTM D 3675
ASTM E 662 |
Is < 25
Ds (1.5) < 100,
Ds (4.0) < 175 |
| Seat Frame, Seat Shroud
(1, 2) |
ASTM E 162
ASTM E 662 |
Is < 35
Ds (1.5) < 100,
Ds (4.0) < 200 |
| Upholstery
(1, 2, 3, 6, 7, 8) |
14 CFR (FAR) 25.853
(Appendix F, vertical, textiles)
ASTM E 662 |
Flame Time < 10 sec.
Burn Length < 150 mm,
(6").
Ds (4.0) < 200 |
| Wire Insulation
(1, 2, 19) |
IEEE Std 383 -
Flammability
ASTM E 662 |
Pass
Ds (4.0) < 50
|
Note: The smoke density for the wiring
is currently listed as ASTM Ds (4.0) < 50.
This is much less than previous values of ASTM Ds (4.0) <
75(NF) and ASTM Ds (4.0) < 200 (F) used on
other projects.
The value of 50 was first used by BART on the C1, C3, later used on
the TTA specification and finally with the New MBTA specs.
| Numbered comments are based upon NFPA 130, and 49 CFR Appendix B
to Part 238. These comments have been either quoted, combined
from both, or adapted/edited to passenger transit applications.
1) Materials tested for
surface flammability shall not exhibit any flaming running or
dripping unless an appropriate fire hazard analysis is conducted
and approved by the Transit Authority.
2) The ASTM E 662-97
maximum test limits for smoke emission (specific optical density)
shall be measured in both the flaming or non-flaming mode, values
shall be provided for both cases.
3) Testing of a complete
seat assembly (including cushions, fabric layers, upholstery)
according to ASTM E 1537 using the pass/fail criteria of California
Technical Bulletin 133, and testing of a complete mattress assembly
(including foam and ticking) according to ASTM E 1590 using
the pass/fail criteria of California Technical Bulletin 129
shall be permitted in lieu of the test methods prescribed herein,
provided the assembly component units remain unchanged or new
(replacement) assembly components possess equivalent fire performance
properties to the original components tested. Testing shall
be at 50 kW/m2 applied heat flux with a retainer
frame. A fire hazard analysis must also be conducted that considers
the operating environment within which the seat or mattress
assembly will be used in relation to the risk of vandalism,
puncture, cutting, or other acts which may expose the individual
components of the assemblies to an ignition source. The requirements
of Notes 5, 6, 7, and 8 shall be met.
4) Testing is performed
without upholstery.
5) The surface flammability
and smoke emission characteristics shall be demonstrated to
be permanent after dynamic testing according to ASTM D 3574,
Test I 2 (Dynamic Fatigue Test by the Roller Shear at Constant
Force) or Test I 3 (Dynamic Fatigue Test by Constant Force Pounding)
both using Procedure B, except that the test samples shall be
a minimum of 6 inches (154 mm) by 18 inches (457 mm) by the
thickness of the material in its end use configuration, or multiples
thereof. If Test I 3 is used, the size of the indentor described
in paragraph 96.2 shall be modified to accommodate the specified
test specimen.
6) The surface flammability
and smoke emission characteristics shall be demonstrated to
be permanent by washing, if appropriate, according to FED-STD-191a
Textile Test Method 5830.
7) The surface flammability
and smoke emission characteristics shall be demonstrated to
be permanent by dry-cleaning, if appropriate, according to ASTM
D 2724-87.
8) Materials that cannot
be washed or dry-cleaned shall be so labeled and shall meet
the applicable performance criteria after being cleaned as recommended
by the manufacturer.
9) As a minimum, all
combustible materials used anywhere in the vehicle (except as
noted in 10) are required to be tested including interior, cab
components as well as exterior components. Combustible signage
shall not be required to meet flame spread or smoke emission
requirements if (a) the actual thickness of the signage is no
greater than 1.5 mm (0.060 in.); (b) the aggregate area of combustible
signage does not exceed 10 percent of the wall area of the car,
including windows; and (c) no single sign is larger than 0.47
m2 (5.0 ft2). Items that
can not be made compliant due to other dominating engineering
requirements may not be required to meet the flammability or
smoke emission performance criteria specified, but still must
be tested to establish the relative risk and evaluated, and
waived, by the Transit Authority.
10) Materials used to
fabricate miscellaneous, discontinuous small parts (such as
knobs, rollers, fasteners, clips, grommets, and small electrical
parts) that will not contribute materially to fire growth in
end use configuration are exempt from flammability and smoke
emission performance requirements, provided that the surface
area of any individual small part is less than 16 square inches
(100 cm2) in end use configuration and an
appropriate fire hazard analysis is conducted which addresses
the location and quantity of the materials used, and the vulnerability
of the materials to ignition and contribution to flame spread.
11) If the surface area
of any individual small part is less than 16 square inches (100
cm2) in end use configuration, materials used
to fabricate such a part may be tested in accordance with ASTM
E 1354 as an alternative to both (a) the ASTM E 162 flammability
test procedure, or the appropriate flammability test procedure
otherwise specified in the table, and (b) the ASTM E 662 smoke
generation test procedure. Testing shall be at 50 kW/m2
applied heat flux with a retainer frame. Materials tested in
accordance with ASTM E 1354 shall meet the following performance
criteria: average heat release rate (q˙ ´´ 180) less
than or equal to 100 kW/m2, and average specific
extinction area (sf) less than or equal to 500 m2/kg
over the same 180-second period.
12) Carpeting used as
a wall or ceiling covering shall be tested according to ASTM
E 162 and ASTM E 662 and meet the respective criteria of I s
less than or equal to 35 and D s (1.5) less than or equal to
100 and D s (4.0) less than or equal to 200. Notes 1 and 2
apply.
13) Floor covering shall
be tested with padding in accordance with ASTM E 648, if the
padding is used in the actual installation.
14) For double window
glazing, only the interior glazing is required to meet the requirements
specified herein. (The exterior glazing is not required to
meet these requirements.)
15) Average flame propagation
shall be less than 4 inches and no specimen shall be completely
consumed.
16) Penetrations (ducts,
access openings, etc.) shall be designed against acting as passageways
for fire and smoke and representative penetrations shall be
included as part of test assemblies.
17) A structural flooring
assembly separating the interior of a vehicle from its undercarriage
shall meet the performance criteria during a nominal test period
as determined by the railroad. The nominal test period must
be twice the maximum expected time period under normal circumstances
for a vehicle to stop completely and safely from its maximum
operating speed, plus the time necessary to evacuate all the
vehicle's occupants to a safe area. The nominal test period
must not be less than 15 minutes. Only one specimen need be
tested. A proportional reduction may be made in the dimensions
of the specimen provided it serves to truly test the ability
of the structural flooring assembly to perform as a barrier
against under-vehicle fires. The fire resistance period required
shall be consistent with the safe evacuation of a full load
of passengers from the vehicle under worst-case conditions.
18) Portions of the vehicle
body which separate major ignition sources, energy sources,
or sources of fuel-load from vehicle interiors, shall have sufficient
fire endurance as determined by a fire hazard analysis acceptable
to the railroad which addresses the location and quantity of
the materials used, as well as vulnerability of the materials
to ignition, flame spread, and smoke generation. These portions
include equipment carrying portions of a vehicle's roof and
the interior structure separating the levels of a bi-level car,
but do not include a flooring assembly subject to Note 17.
19) Testing shall be
conducted in accordance with ANSI/IEEE Standard 383-1974, section
2.5, with the additional requirement that circuit integrity
shall continue for 5 minutes after the start of the test. |
Toxic Content Limits In Combustion Products
The maximum toxic gas concentration in the combustion
products of any materials used in the construction of the vehicle shall
not exceed the following values:
Toxic Gas – BSS-7239
(or Bombardier SMP 800-C) |
Maximum Concentration |
| Carbon Monoxide (CO), |
3500 ppm |
| Hydrogen Fluoride (HF), |
200 ppm |
| Nitrogen Dioxide (NO2), |
100 ppm |
| Hydrogen Chloride (HCL), |
500 ppm |
| Hydrogen Cyanide (HCN), |
150ppm |
| Sulfur Dioxide (SO2), |
100 ppm |
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