April 25, 2012 www.element.com

Brent L. Larson, Project ManagerElement Materials Technology, St. Paul, MN

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

Mattress Fire Testing

Things To Keep In Mind

1. If you are disconnected during the presentation

You should be able to log right back in.

2. 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).

3. 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.

2

Mattress Fire Testing

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

3

Mattress Fire Testing

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)

4

Mattress Fire Testing

CPSC CFR 1632 (Mattress/Mattress Pad Test)

5

Mattress Fire Testing

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

6

Mattress Fire Testing

CPSC CFR 1632 (Ticking Substitution Test)

7

Mattress Fire Testing

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)

8

Mattress Fire Testing

CPSC CFR 1632 (Tape Edge Substitution Test)

9

Mattress Fire Testing

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

10

Mattress Fire Testing

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

11

Mattress Fire Testing

California TB 121

12

Mattress Fire Testing

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

13

Mattress Fire Testing

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

14

Mattress Fire Testing

California TB 129 (setup with foundation)

15

Mattress Fire Testing

California TB 129 (setup without foundation)

16

Mattress Fire Testing

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

17

Mattress Fire Testing

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

18

Mattress Fire Testing

Boston Fire Department

19

Mattress Fire Testing

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

20

Mattress Fire Testing

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

21

Mattress Fire Testing

CPSC CFR 1633 Open Flame Test

22

Mattress Fire Testing

CPSC CFR 1633 Open Flame Test

23

Mattress Fire Testing

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

24

Mattress Fire Testing

Now What ??

25

Mattress Fire Testing

Are All of These Tests Required (or even necessary)?

• The short answers are: YES and TBD

26

Mattress Fire Testing

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

27

Mattress Fire Testing

Minimum Requirements to Sell in the US

• Will the 1632 cigarette test be phased out?

• Not likely anytime soon.– WHY?

• lack of data

28

Mattress Fire Testing

Minimum Requirements to Sell in California

• CPSC 1632/1633

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

29

Mattress Fire Testing

1633 / TB 129 Comparison

30

TEST 1633 TB 129

Pass/Fail - Peak Rate of Heat Release:

200 kW 100 kW

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

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

Ignition Source:propane burners

top & side

propane burner

(side of bed, dual jets)

Application Time: 70 sec/50 sec 3 minutes

Test Duration: 30 minutes 60 minutes

Mattress Fire Testing

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.)

31

Mattress Fire Testing

1633 / Boston IX-11 Comparison

32

TEST 1633 Boston IX-11

Pass/Fail - Peak Rate of Heat Release:

200 kW 150 kW*

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

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

Ignition Source:propane burners

top & side

bed cloths

(sheets, blanket, 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

Wrap Up: Common Questions

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

33

Mattress Fire Testing

Wrap Up: Common Questions

34

TEST TB 121 TB 129Boston IX-

111633

Pass/Fail - Peak Rate of Heat Release:

n/a 100 kW 150 kW* 200 kW

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

Pass/Fail: Mass Loss:Over 10%

@ 10 min3 lbs @ 10 min

weight of bed cloths*

n/a

Ignition Source:Wadded

newspaper

propane burner

(side of bed, dual jets)

bed cloths

(sheets, blanket, pillow)

propane burners

top & side

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

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

Mattress Fire Testing

To Get More Information

• MY CONTACT INFOPhone: 651 659 7218Cell: 651 248 8847Email: brent.larson@element.comWebsite: www.element.comConnect to me on LinkedIn

• I will soon be starting a blog to continue the discussion

38