TEST 1 – STACKED PP

Test 1 was conducted as an initial estimate of the required protection for stacked composite intermediate bulk containers with plastic pallets. Based on the make-up of the IBC (plastic wall container supported by plastic pallet), it was assumed that the product would be comparable to an uncartoned plastic [3], since no packaging is present. Protection options are provided for Uncartoned Unexpanded Plastic (UUP) or Uncartoned Expanded Plastic (UEP) in FM Global Loss Prevention Data Sheet 8-9 [4].

IBCS, K202 QR SPRINKLERS @ 49 MM/MIN

Table 5 and Table 6 in Data Sheet 8-9 provide ceiling level protection options for solid-piled UUP or solid-piled UEP, respectively. For a 9.1 m (30 ft) ceiling height, one protection option for the hazard is given for K202 (K14) quick response, pendent sprinklers. For the UUP, the recommended design is 12 sprinklers operating at 3.5 bar (50 psi). For UEP, the recommendation is 12 sprinklers operating at 6.9 bar (100 psi).

For the first test, a protection point between the two commodities was selected. The first test was conducted at a design pressure of 5.2 bar (75 psi). Since the protection options for the quick response sprinkler are based on 12 operating sprinklers, that quantity was used to base the sprinkler operation criteria (see Section 2.7.2). To provide a safety factor of 1.5, only eight sprinklers were allowed to operate for acceptable performance.

3.1.1 Test 1 Details

The test was conducted on August 2, 2011, under the South Ceiling of the Large Burn Lab. The fuel array was stacked empty composite IBCs on plastic pallets. Additional stacks of Class 2 commodity were placed around the array as targets8

7

PP = Plastic Pallet

. The IBCs were stacked 3-high for a storage height of 3.5 m (11 ft 6 in.). The ceiling was set to 9.1 m (30 ft), providing a ceiling

22

clearance of 5.6 m (18 ft 6 in.). Ignition was Under 1 sprinkler, placed in the doghouse of the IBC nominally in the center of the array.

Ceiling level protection was provided by K-factor 202 lpm/bar1/2 (14.0 gpm/psi1/2), pendent, quick response sprinklers, with a 74 oC (165 oF) link. The sprinklers, installed on 3.0 m x 3.0 m (10 ft x 10 ft) spacing, and discharging at a pressure of 5.2 bar (75 psi), resulted in a design discharge density of 49 mm/min (1.2 gpm/ft2).

3.1.2 Test 1 Highlights

The fire was initiated with an igniter placed in the doghouse of the 1st tier9 IBC in the western row10

Figure 3-1

. The fire developed slowly and flames reached the top of the 1st tier IBC at 1 min 34 s. As the IBC became more involved, the fire intensity increased and flames were burning beneath the 2nd tier IBC at 2 min 35 s. Plastic was observed dripping into the center longitudinal flue creating a small plastic pool fire in the flue. At 4 min 33 s, the pool had spread across the flue and the flames were impinging on the eastern row of IBCs across from ignition. At 5 min 16 s, the IBC at the base of the eastern row became involved. The fire intensity increased in the longitudinal flue and flames reached the top of the 1st tier within the flue. At 8 min 54 s, the flames reached the top of the array and at 9 min 13 s, flames were 1.2 m (4 ft) above the array, as

shown in .

The 1st sprinkler operation was at 9 min 24 s and quickly knocked the flames down below the top of the array. At 9 min 48 s, surface ignition on the 2nd tier Class 2 target commodity east of the main array was observed. At 11 min, minimal burning was observed in the array, with only small flames present below the pallets of the 2nd tier commodity. Small fires were present for the remainder of the test in areas below the IBC pallets that were shielded from the sprinkler spray. At 40 min, the test was terminated.

9 _{Although the test was a stacked array, observations and notes throughout the report are based on “tiers,” with the} 1st tier located at floor level, the 2nd tier stacked on top of the 1st, and the 3rd tier at the top of the array.

23

Figure 3-1: Photo of Array at ~9 min 13 s (Test 1)

3.1.3 Test 1 Results

During the test, a single sprinkler operated and quickly reduced the fire intensity. The sprinkler operation pattern is provided in Figure 3-2. The peak ceiling steel temperature measured was 32 oC (89 oF). Post-test observations show that the main area of involvement was in the core IBCs defined as the main array. Ignition of the Class 2 targets was observed, which would indicate an unacceptable result, as specified in Section 2.7.1. However, the involvement of the Class 2 commodity occurred at the same time as the first sprinkler operation and was quickly extinguished upon water application. Based on the material property differences between the corrugated carton of the Class 2 commodity and the walls of an IBC, it was assumed that the target would not have ignited had it been an IBC. For subsequent tests, the stacks of Class 2 directly east and west of ignition were replaced with stacked IBCs. A photo of the post-test damage is provided in Figure 3-3 and the extent of damage is provided in Figure 3-4 through Figure 3-6.

Based on the evaluation criteria, and assuming the flame spread to the Class 2 commodity was not representative of a stacked IBC fire, the sprinkler protection provided was deemed acceptable. Test data plots and test observations are provided in Appendix A and B.

24 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 IBC IBC IBC IBC IBC N SPRINKLER SEQUENCE # Time (m:s) 1 9:24 ProtectIBC001 1

Figure 3-2: Test 1 - Sprinkler Operation Pattern

25 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 IBC IBC IBC IBC IBC N

Figure 3-4: Test 1 Damage - 1st Tier

Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 IBC IBC IBC IBC IBC IBC N

Figure 3-5: Test 1 Damage - 2nd Tier

BREACHED IBC THERMAL DAMAGE Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 IBC IBC IBC IBC IBC IBC N

26 3.2TEST 2 – STACKED PP11

Based on the acceptable results of Test 1, the test was repeated for Test 2 with the same conditions, but with a lower design discharge pressure. The test was conducted at a design pressure of 2.2 bar (32 psi). As with Test 1, only eight sprinklers were allowed to operate for acceptable performance.

IBCS, K202 QR SPRINKLERS @ 33 MM/MIN

3.2.1 Test 2 Details

The test was conducted on August 4, 2011, under the South Ceiling of the Large Burn Lab. The fuel array was stacked empty composite IBCs on plastic pallets. Additional stacked composite IBCs and Class 2 commodity were placed around the array as targets. The IBCs were stacked 3-high for a storage height of 3.5 m (11 ft 6 in.). The ceiling was set to 9.1 m (30 ft), providing a ceiling clearance of 5.6 m (18 ft 6 in.). Ignition was Under 1 sprinkler, placed in the doghouse of the IBC nominally in the center of the array.

Ceiling level protection was provided by K-factor 202 lpm/bar1/2 (14.0 gpm/psi1/2), pendent, quick response sprinklers, with a 74 oC (165 oF) link. The sprinklers, installed on 3.0 m x 3.0 m (10 ft x 10 ft) spacing, and discharging at a pressure of 2.2 bar (32 psi), resulted in a design discharge density of 33 mm/min (0.8 gpm/ft2).

3.2.2 Test 2 Observations

The fire was initiated with an igniter placed in the doghouse of the 1st tier IBC in the western row. Flames from the igniter were 3 ft (0.9 m) in height and extended to the top of the 1st tier at 52 s. At 1 min 58 s, flames were observed entering below the pallets of the 2nd tier commodity. Flames were well established in the pallets below the 2nd tier at 4 min 50 s and, at 5 min 30 s, the flames had traveled up the face of the 1st tier IBCs on both sides of the ignition flue. At 6 min 12 s, the fire intensity increased and flames grew to over 5 ft (1.5 m) in height. At 7 min 14 s, 2nd tier IBCs were involved and flames were over 8 ft (2.4 m) in height. At 7 min 45 s, flames

11 _{PP = Plastic Pallet}

27

below 2nd tier commodity were extending into the east and west longitudinal flues. At 8 min 35 s, flames were above the top of the array.

The 1st sprinkler operated at 8 min 55 s. The flames were quickly knocked down and at 9 min 40 s, the fire was no longer above the top of the array. At 10 min 3 s, flames were no longer present in the east or west longitudinal flues. For the duration of the test, fire persisted below the pallets of the 2nd tier commodity where it was shielded from the overhead sprinkler. However, the fire showed no potential for additional spread through the array and the test was terminated at 30 min.

3.2.3 Test 2 Results

During the test, a single sprinkler operated and quickly controlled the fire. The sprinkler operation pattern is provided in Figure 3-7. A photo of the test array at 1st sprinkler operation is provided in Figure 3-8. The sprinkler was able to prevent fire spread to the target commodity surrounding the main array and most observed damage was prior to the 1st sprinkler operation12

Figure 3-9

. A photo of the post-test damage is provided in and the extent of damage is provided in Figure 3-10 through Figure 3-12.

The peak 1-min average steel temperature measurement of 36 oC (97 oF) was below the evaluation threshold of 538 oC (1000 oF). Based on the evaluation criteria, the sprinkler protection provided was acceptable. Test data plots and test observations are provided in Appendix A and B.

12

Replacing the Class 2 commodity used in Test 1 with empty composite IBCs did not result in target involvement, even though the sprinkler design discharge density was reduced in Test 2.

28 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 IBC IBC IBC IBC IBC IBC IBC N SPRINKLER SEQUENCE # Time (m:s) 1 8:56 ProtectIBC002 1

Figure 3-7: Test 2 - Sprinkler Operation Pattern

29

30 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 IBC IBC IBC IBC IBC N IBC IBC

Figure 3-10: Test 2 Damage - 1st Tier

Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 IBC IBC IBC IBC IBC IBC N IBC IBC

Figure 3-11: Test 2 Damage - 2nd Tier

BREACHED IBC THERMAL DAMAGE Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 IBC IBC IBC IBC IBC IBC N IBC IBC

31 3.3TEST 3 – STACKED PP13

Based on the acceptable results of Test 1 and Test 2, the test was repeated for Test 3 with a further reduction in the design discharge pressure. The test was conducted at a design pressure of 1.2 bar (18 psi). As with the previous tests, only eight sprinklers were allowed to operate for acceptable performance.

IBCS, K202 QR SPRINKLERS @ 24 MM/MIN

3.3.1 Test 3 Details

Test 3 was conducted on August 9, 2011, under the South Ceiling of the Large Burn Lab. The fuel array was stacked empty composite IBCs on plastic pallets. Additional composite IBCs and Class 2 commodity were placed around the array as targets. The IBCs were stacked 3-high for a storage height of 3.5 m (11 ft 6 in.). The ceiling was set to 9.1 m (30 ft), providing a ceiling clearance of 5.6 m (18 ft 6 in.). Ignition was Under 1 sprinkler, placed in the doghouse of the IBC nominally in the center of the array.

Ceiling level protection was provided by K-factor 202 lpm/bar1/2 (14.0 gpm/psi1/2), pendent, quick response sprinklers, with a 74 oC (165 oF) link. The sprinklers, installed on 3.0 m x 3.0 m (10 ft x 10 ft) spacing, and discharging at a pressure of 1.2 bar (18 psi), resulted in a design discharge density of 24 mm/min (0.6 gpm/ft2).

3.3.2 Test 3 Observations

The fire was initiated with an igniter placed in the doghouse of the 1st tier IBC in the western row. Flames extended to the top of the 1st tier at 1 min 52 s. At 2 min 4 s, plastic was observed dripping into the longitudinal flue and at 3 min 37 s, the plastic at floor level was burning. At 4 min 46 s, the fire in the flue was impinging on the eastern row and at 5 min 29 s, the floor level IBC in the east row became involved. At 7 min 6 s, the fire was growing in intensity and flames were 1.8 m (6 ft) in height. At 8 min 49 s flames were exiting the top of the array.

13 _{PP = Plastic Pallet}

32

The 1st sprinkler operation was at 9 min 19 s, but had little impact on the fire. Flames remained above the top of the array and continued to spread into the longitudinal flues on either side of the main array. As the IBCs in the main array were consumed, they began to collapse, with several collapsing between 10 min 42 s and 11 min 11 s. The IBCs involved were continually dripping plastic into the flue space and spreading into the target IBCs. At 13 min 30 s, the fire spread to the 1st tier IBCs of the eastern target. At 14 min 13 s, flames were exiting the array above the east longitudinal flue. At 14 min 50 s, flames were observed exiting below the target IBCs beyond the extent of the test array.

At 16 min 59 s, the 2nd sprinkler operated and at 17 min 15 s, a total of six sprinklers was operating. At 17 min 20 s, the fire had spread to the Class 2 target commodity. The operating sprinklers did have an impact on the fire and at 19 min 12 s, the fire intensity had decreased and flames were no longer present above the array. At 20 min, flames were only present below the pallets where they were shielded from the sprinkler spray. The test was terminated at 30 min.

3.3.3 Test 3 Results

During the test, six sprinklers operated but were not able to prevent fire spread through the array. The sprinkler operation pattern is provided in Figure 3-13. A photo of the test array after the 1st sprinkler operation is provided in Figure 3-14. A photo of the array prior to the 2nd sprinkler operation showing the fire spread into the target IBCs is provided in Figure 3-15. A photo of the post-test damage is provided in Figure 3-16 and the extent of damage is provided in Figure 3-17 through Figure 3-19.

The peak 1-min average steel temperature measurement of 46 oC (114 oF) was below the evaluation threshold of 538 oC (1000 oF). Based on the evaluation criteria, the sprinkler protection provided was not acceptable. Test data plots and test observations are provided in Appendix A and B.

33 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 IBC IBC IBC IBC IBC IBC IBC N SPRINKLER SEQUENCE # Time (m:s) 1 2 3 4 5 6 9:19 16:59 17:02 17:09 17:14 17:15 ProtectIBC003 1 4 5 3 2 6

34

Figure 3-14: Photo of Array after 1st Sprinkler Operation ~9 min 40 s (Test 3)

35

36 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 IBC IBC IBC IBC IBC N IBC IBC

Figure 3-17: Test 3 Damage - 1st Tier

Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 IBC IBC IBC IBC IBC IBC N IBC IBC

Figure 3-18: Test 3 Damage - 2nd Tier

BREACHED IBC THERMAL DAMAGE Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 IBC IBC IBC IBC IBC IBC N IBC IBC

37 3.4TEST 4 – STACKED WP14

Tests 1-3 were used to determine the sprinkler protection required for stacked composite IBCs on plastic pallets. Test 2 generated an acceptable result at a design density of 33 mm/min (0.8 gpm/ft2); however, acceptable results were not observed when the design density was reduced to 24 mm/min (0.6 gpm/ft2).

IBCS, K202 QR SPRINKLERS @ 24 MM/MIN

Test 4 was conducted with stacked composite IBCs on wood pallets. It was assumed that the wood pallet IBCs would pose less of a hazard than the plastic pallet IBCs. Therefore, the successful result in Test 2 can be applied to the wood pallet IBCs. To verify if the wood pallet IBCs were less hazardous, Test 4 was conducted with the design density that was not successful for the plastic pallet IBC test. The test was conducted at a design pressure of 1.2 bar (18 psi). As with the previous tests, only eight sprinklers were allowed to operate for acceptable performance.

3.4.1 Test 4 Details

Test 4 was conducted on August 10, 2011, under the South Ceiling of the Large Burn Lab. The fuel array was stacked empty composite IBCs on wood pallets. Additional composite IBCs and Class 2 commodity were placed around the array as targets. The IBCs were stacked 3-high for a storage height of 3.5 m (11 ft 6 in.). The ceiling was set to 9.1 m (30 ft), providing a ceiling clearance of 5.6 m (18 ft 6 in.). Ignition was Under 1 sprinkler, placed in the doghouse of the IBC nominally in the center of the array.

Ceiling level protection was provided by K-factor 202 lpm/bar1/2 (14.0 gpm/psi1/2), pendent, quick response sprinklers, with a 74 oC (165 oF) link. The sprinklers, installed on 3.0 m x 3.0 m (10 ft x 10 ft) spacing, and discharging at a pressure of 1.2 bar (18 psi), resulted in a design discharge density of 24 mm/min (0.6 gpm/ft2).

14 _{WP = Wood Pallet}

38 3.4.2 Test 4 Observations

The fire was initiated with an igniter placed in the doghouse of the 1st tier IBC in the western row. Flames extended to the top of the 1st tier at 1 min 30 s. At 3 min 10 s, the plastic from the ignition IBC began to melt and drip into the flue. At 4 min 55 s, the fire had spread to the IBCs in the first tier of the eastern row. Flames continued to spread through the array and were observed in the western longitudinal flue at 7 min 20 s. Flames reached the top of the array at 7 min 40 s.

The 1st sprinkler operation was at 8 min 24 s. The fire was quickly knocked down with some flames remaining below the 2nd tier pallets in the longitudinal flues. At 12 min, only small flames were observed beneath pallets where the fire was shielded from the sprinkler spray. The test was terminated at 20 min.

3.4.3 Test 4 Results

During the test, a single sprinkler operated and quickly controlled the fire. The sprinkler operation pattern is provided in Figure 3-20. Only localized burning in shielded areas remained for the duration of the test and the fire was contained to the main array. A photo of the test array at 1st sprinkler operation is provided in Figure 3-21. A photo of the post-test damage is provided in Figure 3-22 and the extent of damage is provided in Figure 3-23 through Figure 3-25.

The peak 1-min average steel temperature measurement of 37 oC (98 oF) was below the evaluation threshold of 538 oC (1000 oF). Based on the evaluation criteria, the sprinkler protection provided was acceptable. Test data plots and test observations are provided in Appendix A and B.

39 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 IBC IBC IBC IBC IBC IBC IBC N SPRINKLER SEQUENCE # Time (m:s) 1 8:24 ProtectIBC004 1

40

Figure 3-21: Photo of Test Array just Prior to 1st Sprinkler Operation (Test 4)

41 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 IBC IBC IBC IBC IBC N IBC IBC

Figure 3-23: Test 4 Damage - 1st Tier

Class 2 Class 2