Fire Prevention and Protection Section Chapter 1-Safe Work Environment

Fire Prevention and Protection Section
Chapter 1- Safe Work Environment

Author Technical Contact Revision Approver Name Effective Date
Level
Global Security Tim Sullivan 6 Jim Ellis 09/29/09
1.0 PURPOSE
This chapter provides standards and additional information to assist GM leaders

with their responsibility to help employees realize a healthy, injury-free work
environment. GM leadership is committed to protecting the health and safety of
each employee as the overriding priority of this company.
2.0 SCOPE
The following standards relate to providing fire prevention and emergency

management programs for GM facilities commensurate with the risks.
The requirements listed in this Chapter apply to GM owned and managed facilities
globally. Applicable local regulations may supersede the GM standards.
3.0 STANDARDS
3.1 Emergency Egress
Design and install emergency egress components to meet applicable laws and
regulations. Design new facilities to allow for prompt egress.
Conduct periodic inspections of emergency egress components as outlined in the

FPG-10 Egress Components Inspection Guideline located on the GM Global
Security website, Fire Guidelines web page.
Do not interrupt the path of travel along a means of egress by any building element
other than a component of the means of egress.
3.1.1 Aisles
Arrange aisles to provide a continuous egress path. Aisles must be sufficiently

wide to permit safe egress of personnel and for the safe operation of implant fire
fighting apparatus, if applicable. Aisles must be kept clear of storage.
3.1.2 Exits
Provide adequately identified, clearly visible and accessible means of egress in

each building for evacuation of personnel in the event of an emergency.
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In new office buildings with two or more floors, provide at least two means of exit,
remote from each other, for each floor. These exit pathways must include fully
enclosed fire-rated stairways leading directly to the outside.
3.1.3 Stairs
Arrange stairs and other means of exit to clearly identify the direction of egress to a
public way.
Do not store materials in stairwells.
3.1.4 Lighting/Power
Provide adequate emergency lighting in the event of power failure.
3.1.5 Egress Planning Requirements
Establish an evacuation procedure for each facility.
Post evacuation diagrams in appropriate locations within the facility.
For non-manufacturing buildings, such as offices and engineering centers, with

three or more stories above grade level, complete and document using the High
Populated Facilities – Emergency Egress Survey annually.
For one or two story non-manufacturing buildings that meet the following criteria:
one or two stories
non-manufacturing
non-warehousing
stand alone – not part of a campus
limited or no security presence
Complete and document a Low-Rise Life Safety Evaluation Survey annually.
3.1.6 Signage
Provide visible exit signs and exit lighting as necessary to direct employees toward
exits.
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3.2. Emergency Notification Systems
Ensure emergency notification signals are distinguishable from other signaling

systems within a building.
Ensure occupant notification systems are capable of producing distinct visual

and/or audible signals for the following:
Evacuation
Take Cover
All Clear
These audible signals should be tested on an annual frequency.
3.3 Emergency Response Planning
3.3.1 Emergency Response Coordinating Team Organization
Establish an Emergency Response Coordinating Team (ERCT) to ensure

adequate response to emergency situations. A member of top management must
serve as the leader of this team to coordinate activities of the ERCT. See Chapter
1, Emergency Response Planning in the Emergency Response section of the
Manual for additional information.
3.3.2 Emergency Response Plans
An Emergency Response Plan (ERP) must be developed and maintained by the

ERCT to cover emergency situations. Ensure the content of the local ERP
includes plans for reasonably foreseeable emergencies based on the occupancy,
location and other factors specific to the site. See the GM Emergency Response
Plan Templates on the Global Security website and Chapter 1, Emergency
Response Planning in the Emergency Response section of the Manual for
additional information.
3.3.4 Emergency Reporting
Prominently display the telephone number to call for assistance in the event of fire
or other emergencies on or near each facility telephone to ensure a prompt
response is obtained.
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3.4 Welding & Cutting (Hot Work) Operations
Establish a written hot work permit process at each facility. Hot work includes
welding, cutting, grinding, or similar processes. The permit system must be under
the control of Security.
Permit procedures also apply to new building construction activities and demolition
activities.
3.4.1 Permit System Requirements
Prior to the performance of any welding, cutting, grinding or allied processes, a

written permit must be obtained from security or their designee.
Before welding or cutting is permitted, the individual issuing the permit must
inspect the area in which cutting or welding is to be performed and determine the
hazards and the precautions to be taken.
The inspection must include specifying the appropriate fire extinguishing

equipment necessary at the work site.
The inspection must also verify that the cutting and welding equipment to be
used is in satisfactory operating condition, and in good repair.
Prior to issuing a permit where flammable liquids are stored, dispensed, handled
and/or sprayed, approval from a security supervisor must be obtained. Additional
precautions for a paint spray booth permit must be developed at the local level.
The permit must indicate the area and type of operation for which it applies. If the
welding or cutting operation is moved from the original area, a new permit must be
obtained for each new location.
Each person welding or cutting must be issued a separate permit. The individual
must be present for the inspection prior to the permit being issued and the permit
must be issued directly to the person welding or cutting.
The permit must expire upon completion of the job at any one location. If work at a
location continues for more than one shift, a new permit must be issued for each
shift.
The permit must be denied if:
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The area contains fire hazards which cannot be eliminated
OR
Sprinklers are out of service in the area and available alternative means of
protection are insufficient.
See General Motors FPG-28 Hot Work - Cutting, Welding, and the Allied
Processes Guideline and FPG-18 Fire Prevention & Protection for Roofing
Operations Requiring Open Flame Guidelines for guidance.
3.5 Fire Protection Impairment Management
Develop a written program for reporting, monitoring, and managing impairments of

fire protection systems and equipment through to resolution.
Manage impairments to fire protection systems and equipment in accordance with

the provisions of General Motors FPG-19 Fire Protection - Detection System
Impairment Management.
3.6 Fire Protection Equipment Inspection
Establish a program which includes procedures for the inspection, testing and
maintenance of fire protection related equipment and devices at each facility.
Document all inspection, testing and maintenance schedules and results, with
records retained in accordance with GM Information Lifecycle Management (ILM)
retention schedules and local code requirements, if applicable.
3.6.1 Required Inspections
Ensure the fire protection inspection, testing and maintenance program includes
the equipment and system components identified below. Guidance on additional
fire protection equipment inspection, testing and maintenance may be found on the
GM Global Security Fire Guidelines website.
3.6.1.1 Fire Barrier Partitions and Fire Walls
Establish a regular inspection procedure to ensure fire barrier partitions and fire
walls remain continuous and intact.
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3.6.1.2 Heat and Smoke Vents
Visually inspect Heat and smoke vents annually to ensure their functionality.
3.6.1.3 Water Supply Facilities
Conduct a routine maintenance inspection of the water supply facilities. Maintain

reservoirs at the appropriate level at all times.
3.6.1.4 Fire Pumps
Conduct weekly fire pump testing. Pumps must be automatically started and
arranged for manual stop.
3.6.1.5 Fire Protection Mains and Hydrants
Maintain the fire protection mains, including hydrants, free of obstructions and in
proper operating condition.
3.6.1.6 Fire Protection System Valves
Visually inspect system control, sectional control, fire pump, water supply and all
other fire protection valves two inches (51 mm) or larger at least weekly (monthly if
locked or supervised) to ensure they are in the normal position and properly
maintained.
3.6.1.7 Automatic Sprinkler Systems
Test each wet pipe sprinkler system quarterly at the inspector’s test connection to
assure the waterflow alarm device is functioning properly and the signal is received
at the alarm system control station.
Inspect dry pipe valve enclosures at least daily (weekly if temperature is

electronically supervised) when the potential for freezing exists.
3.6.1.8 Exterior/Interior Fire Hose and Roof Hose Cabinets
On a quarterly schedule, inspect each fire hose location and roof hose cabinet to
ensure all equipment is in place, there are no obstructions and the hose has not
been damaged.
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3.6.1.9 Emergency Lighting
Inspect emergency lighting facilities monthly. Battery trickle charge units’

electrolyte levels must be checked and the test button operated.
Start emergency generators on a monthly basis.
3.6.1.10 Proprietary Alarm System
Test the following initiating and transmitting devices to assure the alarms are
received at the proprietary alarm console:
Waterflow alarms – quarterly
Supervised valves – semi-annually
Manual pull alarms – annually
Smoke/Heat detectors – annually
3.6.1.11 Fire Trucks
Inspect and test the site fire truck on at least a weekly basis.
3.6.1.12 Portable Fire Extinguishers
Perform a visual inspection monthly to ensure portable extinguishers are available

and are operational.
Perform maintenance on each extinguisher annually and when indicated by an

inspection.
3.6.1.13 Ovens and Furnaces
Perform functional testing of combustion safety controls for fuel-fired equipment

annually.
Establish a regular inspection of drying ovens to ensure combustible residues are

kept to a minimum.
3.7 Smoking
Prohibit smoking in locations containing a potential fire or explosion hazard.

Designated “No Smoking” areas must be conspicuously posted with signs and/or
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floor markings to indicate the extent and nature of the hazard. Develop written
smoking regulations for each facility.
3.8 Housekeeping
Remove all combustible waste, rubbish, debris, and other trash material from work
areas as soon as practical and do not allow these materials to accumulate.
3.9 Fire Response
3.9.1 Personnel Evacuation
Emergency response planning must include development of an evacuation plan for

employees, contractors, visitors and other personnel. The General Motors
Emergency Response Plan Templates provide additional detail. These are located
on the GMGS, Emergency Response web page.
3.9.2 Alarm Response
Every fire-related alarm must be investigated by Security or by management for

smaller locations without on-site security.
3.9.3 Manual Firefighting
Establish an incipient stage fire brigade for each General Motors manufacturing
facility. Structural fire brigades are required for any General Motors manufacturing
facilitiy if the public fire response is insufficient.
3.10 Fire Incident Reporting
3.10.1 Fire-Related Incident Reporting
Report all fire-related incidents to Global Security. Complete the GM Global

Security Incident Form via the Global Reporting Investigations Tool (GRIT)
available on the GMGS website.
Reportable losses include: all fires, explosions, water-based protection system

failures, special hazard protection system discharge and natural disasters.
Reports must be submitted for all fire-related losses.
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3.10.2 Fire Incident Notification
Immediate notification (within one hour) should be made to the Global Security
Staff for the following:
Incidents involving fatalities or injuries.
All losses with damage exceeding $500,000 USD.
Suspected arson incidents (GM Global Security Investigations must be

contacted immediately if arson is suspected).
Any major fire protection impairment impacting site water supply capability, special
hazard processes, or sprinkler coverage for more than eight sprinkler systems,
must be reported by telephone to the Global Security Staff within 24 hours of
occurrence;
Follow all telephone notifications with the submission of a GMGS Incident Form.
(See INVG-03-A3 Notification & Reporting Template) Local reporting procedures
relative to divisional, group or subsidiary practices must also be followed.
3.11 Building Construction and Demolition
Applicable standards throughout this Chapter also apply during construction and
demolition activities. See the operations guideline SECG-12 Site Security During
New Construction for additional information.
3.11.1 Security Responsibilities
Assign a Security person to ensure fire prevention and protection requirements are
adhered to by the contractors. This individual will also support the GM
Construction Managers in overseeing the installation of fire protection such as
underground fire main installation, sprinkler systems, etc.
3.11.2. General Contractor Responsibilities
Include a fire safety program in all construction, alteration, or demolition contracts,

and establish the right of the owner to administer and enforce this program, even
though the building may be entirely under the jurisdiction of the general contractor.
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The fire safety program is the responsibility of the General Contractor and must be
included in the contract or purchase order agreement.
4.0 RECORDS
GM FPG Inspection Forms Field Copy (printer-friendly version)
5.0 REFERENCES
GMGS Manual, Emergency Response Section, Chapter 1
5.1 GM Fire Guidelines and Fire Best Practices
FPG-28 Hot Work - Cutting, Welding, and the Allied Processes Guideline
FPG-18 Fire Prevention & Protection for Roofing Operations Requiring Open
Flame Guideline
FPG-19 Fire Protection – Detection System Impairment Management Guideline
6.0 REVISION HISTORY
Date Revision Level Change Description

3/01/2009 1 Complete Section rewrite
8/17/2009 2 Revised Fire Guidelines
9/29/2009 3 Revised Technical Contact
10/04/2010 4 Clarified Fire Brigade Decision Tree
Applicability
6/02/2011 5 Deleted section 3.3.2 Emergency
Operation Center and added new
Emergency Response references.
9/26/2012 6 Revised section 3.9.3 Manual Firefighting
7.0 DEFINITIONS
Emergency: An unforeseen combination of circumstances requiring immediate

attention that normally can be managed at the local level.
Emergency Egress Components: Emergency egress components are the physical

facility features that allow for prompt escape of occupants from buildings or, where
desirable, into safe areas within buildings. Egress components include exits,
doors, stairwells, lighting, corridors, aisle ways, alarms and door hardware.
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Emergency Management: Organized analysis, planning, decision-making, and

assignment of available resources to mitigate, prepare for and respond to the
effects of all hazards.
Hazard: A dangerous event or circumstance that has potential to lead to an

emergency. Natural hazards are caused by nature and pose a threat to lives,
property and other assets. Technological hazards are caused by tools, machines
and substances we use in everyday life. Manmade hazards, such as acts of
terrorism and riots, are deliberately caused by people.
8.0 APPENDIX
Material contained in this appendix provides additional detail, clarification and

support of the related standards. It contains explanatory material numbered to
correspond with the related standards contained in this chapter.
8.3.1.2 Exits
For new construction, two exits are desirable for high hazard rooms such as the
following:
Engine Test Cells
Engine Test Cell Enclosure
Engine Hot Test Areas
Flammable Storage Rooms
Flammable Dispensing and Mixing Rooms
Liquid Spray and Powder Coating Finishing
Dipping and Coating Operations
8.3.1.5 Egress Planning Requirements
Provisions for prompt employee evacuation should be made, where periodic

temporary obstructions of means of egress occur, for example; train wells, bridges,
ramps, tunnels etc.
The needs of persons with mobility impairments should be given consideration in

the design of evacuation routes and evacuation procedures.
Diagrams should clearly identify emergency routes from the building and to
designated shelter areas. This may be accomplished by the use of floor plans or
workplace maps that clearly show the emergency escape routes. Color-coding
may aid employees in determining their route assignments.
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8.3.2. Emergency Notification Systems
Notification Appliances
Audible devices should be of the speaker type and be sized appropriately for the
application.
The system should be designed to a sound level at least 15 decibels above the
average ambient noise level taken over a 24-hour period using a calibrated testing
device.
Visual notification appliances should be provided as follows:

Areas with average ambient sound levels greater than 105dba
As needed to accommodate employees with hearing disabilities
As required by local law.
Evacuation Signal
Occupant notification systems should be capable of producing distinct visual

and/or audible signals in selected zones with selection of signal type. In large
facilities with multiple buildings, the facility occupant notification system should be
divided into multiple separate notification systems controlled by the fire alarm
system.
The occupant notification system components should be activated and supervised

for system integrity at the Supervising Station through the fire alarm system control
units. Notification systems should be installed with all primary and secondary
power requirements at each location. The notification system should be capable of
signal tones, control patterns and zones as defined for the following minimum
types of events.
Evacuation
Take Cover
All Clear
Voice Communication
Appropriate live or recorded voice annunciation may be used in addition to the

above signals.
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All speakers should be designed for use with the specific fire alarm system and
electrically supervised.
8.3.3.2 Emergency Response Plans
The Emergency Response Plan (ERP) should contain general information

applicable to all or many emergencies, such as evacuation procedures, and
specific plans and procedures for each type of emergency that could reasonably
be expected to occur at the location. A list of telephone numbers and contact
persons should be integral to every ERP. The ERCT should meet on a regular
basis, but at least annually, to verify the ERP is complete and that all
responsibilities are appropriately defined. Guidelines for responding to specific
types of emergencies are located in the GM ERP Template, which can be found on
the GM Global Security Emergency Response page under Procedures/Guidelines.
The public fire service should be invited to visit the facility on an annual basis to
coordinate their response plans and standard operating procedures with the
facility’s Emergency Response Plan. The public fire service should also be made
aware of site processes and high hazard areas. The establishment of staging
areas and diagrams for the public fire service use is recommended. Simulated fire
responses by the public fire service and other surrounding communities can
provide beneficial planning information.
In areas where the public fire service has limited resources, the local facility should
assure that appropriate mutual aid agreements with neighboring public fire service
agencies exist. A close working relationship should be established between
appropriate facility personnel and the public fire service.
8.3.6.1.1 Fire Barrier Partitions and Fire Walls
A monthly inspection procedure should be established for all communicating

openings which are protected by fire doors, shutters or water spray to ensure that
the operating features of these devices are in place and operable.
8.3.6.1.2 Heat and Smoke Vents
Observation should be made to assure that vents are not wired or bolted shut and
linkage mechanisms are free to operate quickly in the event of an emergency.
Powered vents may be designed to operate upon sprinkler water flow. In such
cases, operation of the vents should be verified while conducting waterflow alarm
testing.
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8.3.6.1.4 Fire Pumps
All diesel-driven fire pumps should be automatically started at least weekly and
operated for at least 30 minutes. Electrically driven fire pumps should be
automatically started weekly and operated for a minimum of ten minutes.
Enclosures for fire pumps should be locked or otherwise secured.
8.3.6.1.5 Underground Loop and Hydrants
The underground loop or ring main, including all hydrants, should be flushed
annually. Hydrant houses should be sealed or, if located outside the fenced area,
equipped with locks. Emergency responders should be given key access. Hydrant
houses should be inspected at least monthly to ensure all equipment is available
and maintained in good condition.
8.3.6.1.7 Automatic Sprinkler Systems
Each dry pipe valve should be tested, cleaned and reset annually during warm
weather.
A periodic review of the sprinkler piping and heads throughout the facilities should
be conducted. Bent piping, broken hangers, damaged sprinklers, etc., should be
corrected. Sprinklers coated with paint overspray should be replaced. Sprinklers in
paint spray booths, flow coaters or other flammable or combustible coating
operations should be covered and the coverings replaced frequently so that heavy
deposits of residue do not accumulate.
Periodic flush testing of sprinkler systems should be completed.
8.3.6.1.12 Portable Fire Extinguishers
An inspection record should be affixed to the extinguisher, unless a centralized

recordkeeping system, such as bar coding is used.
8.3.9.2 Alarm Response
Management and Security personnel at each facility should establish clearly

defined procedures for when notification of the public fire service is required.
Procedures authorizing delay in the notification of the public fire service should be
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agreed upon by site management, site security personnel and reviewed with the
local responding fire service, if required.
Specific personnel with radio communications should be assigned to respond to

and attend the fire pumps to ensure the equipment is operating properly during the
emergency.
8.3.9.3 Manual Firefighting
Stand-alone non-manufacturing locations may elect to provide evacuation

procedures as an alternate to brigade activities. This approach should be properly
stated and practiced in accordance with the written emergency response plan for
the location. A fire brigade may be needed for non-manufacturing locations where
public fire response is deemed insufficient.
The site should have an effective method of alerting fire brigade personnel and
indicating the area of the fire.
Fire Brigade – Incipient Stage
Composition
A fire brigade should be maintained for each shift at assembly, manufacturing and
warehousing facilities. The majority of fire situations occur when the site is
occupied. However, the fire brigade should be of sufficient size to respond to
emergency situations at any time.
The composition and level of training of the brigade will vary from location to
location. The basic nucleus of a volunteer brigade should include security
personnel, maintenance employees, and others as may be necessary. Brigades
may be composed of both primary and secondary members. Primary brigade
members are defined as being directly involved in fire suppression activities.
Secondary members are not directly involved in fire suppression activities. Their
duties may include traffic and crowd control, utilities control, manning of valves and
monitoring of fire pumps.
Training
All primary and secondary fire brigade members should receive training
commensurate with the functions that they are expected to perform. These
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functions are to be specified in the fire brigade organizational statement. At a

minimum, hands-on training is required to be conducted annually for all primary fire
brigade members. Fire brigade members should receive other types of training
and education such as: classroom instruction, review of emergency response
procedures, pre-fire planning and review of special hazards in the workplace.
Simulated conditions that exist at the site should be considered for establishing
props for use in the hands-on training. Fire brigade members are encouraged to
participate in live outdoor fire training sessions to better understand fire potential
and limitations of extinguishing equipment. At various sites permits may be
required from service and/or environmental agencies for this activity.
Fire Brigade - Structural
Composition
Each shift should include a minimum of five personnel trained as structural fire
brigade members. One of these designated personnel should be the leader. The
fire brigade members should perform security or other fire-related duties when not
responding to fires. Support personnel trained at the incipient level may be
required to perform non-structural fire fighting.
The personal protective equipment for structural fire brigade members should be in
accordance with the local fire fighting codes or regulations.
Equipment
Fire Ladders - Ladders intended solely for firefighting purposes, and so identified,
should be placed in suitable and readily accessible places throughout the site or
carried on the fire truck. Locks, seals or similar security devices should be used to
prevent the use of these ladders for purposes other than fire fighting.
In-plant fire trucks may be needed for use by fire brigade personnel. One or more
in-plant vehicles should be provided at large facilities
The following decision tree may be used to determine the appropriate level of fire
brigade for a given facility.
* NOTE: For the purpose of applying this decision tree, a large warehouse is
defined as any warehouse of greater than 500,000 ft2 (46,452 m2).
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Decision Tree.docx
8.3.11.1 Security Responsibilities
A fire prevention and protection supervisor should be appointed prior to actual

construction activity.
8.3.11.2 General Contractor Responsibilities
Fire and security patrols should be made on a frequent basis during non-
construction periods and when particular hazard areas are noted.
General Requirements
A. A roadway should be provided completely around each major building of

the plant site as soon as construction begins so that heavy fire
apparatus can reach all sections of the site. For larger facilities,
temporary mobile fire apparatus may be needed during construction.
B. A telephone or other means should be provided for notifying the public

fire service.
C. Necessary precautions should be taken to eliminate all possible fire

hazards and to prevent damage to any construction work, building
materials, equipment and all other property.
D. Contractors’ field offices, storage sheds and all other temporary

buildings should be located 50 ft. (17.2 m) outside of any building under
construction. The space between the buildings should be kept clear.
E. Vehicles should not be allowed to park within any building under

construction. Vehicle parking on the construction site should be in
designated areas.
F. Mobile construction equipment used in connection with the project

should not be parked within any building except when the construction is
underway and the operator responsible for the vehicle is present.
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G. Paint, paint thinner, gasoline, or any other flammable or combustible

liquids should not be stored within any permanent building under
construction.
H. All waste materials, rubbish, debris, broken concrete, etc., should be

removed as soon as possible and not allowed to accumulate. All
combustible debris should be removed from all buildings at least daily or
more frequently as necessary for safe operations.
I. Sprinkler protection should be fully operational before areas are

occupied with productive operations and/or combustible storage.
J. Good housekeeping practices should be observed. .
K. All roofing materials, roof insulation, etc., should be stored outside of

buildings. Tar kettles are not allowed on or within any building. See
Section 3.4 (Hot Work) for further guidance. No more than one day's
supply of other unpackaged combustible building materials should be
stock piled in any location within the building at any time.
L. Salamanders or other types of temporary heaters are not allowed within

the perimeter of any building after roof decking has been placed over
that area, or the building otherwise closed in, except when the type of
heater and installation are designed and listed by a recognized testing
organization for such use. No more than one day's supply of fuel should
be permitted at each heater.
M. The fire protection water supply, underground mains and hydrants

should be installed and placed in service prior to the installation of the
roof cover.
N. Fire protection water supplies should not be used for construction

purposes unless permitted by the fire prevention and protection
supervisor.
O. Sufficient quantities of fire hose, to easily reach all parts of the building,
field offices, storage sheds, or piles of stored material should be
provided.
P. A sufficient number of fire extinguishers of the proper type should be

available during the construction period.
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Q. Tarpaulins should be fire resistant. The placement and use of tarpaulins

should be approved by the fire prevention and protection supervisor.
R. Cutting and welding operations should be performed in accordance with

written procedures.
S. Legible signs should be placed above all job telephones listing the
emergency telephone numbers.
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Fire
Emergency
Yes
Follow Emergency Action Plan(s)

Fight Fire? A. Evacuation Plan
No B. Critical Operations Shut-down
Yes
Manufacturing, Test Sites or
Large Warehouses
(>500,000 ft2, or 46,452 m2) Type of Offices or CC&A
Occupancy? PDC’s
Legal or Union
Requirements for Yes
Structural Fire
Brigade?
Structural Fire Brigade
Recommended
Yes Yes
Public Fire Response

Capable of Responding
with Adequate Apparatus
and Personnel?
Global Security Review
Recommended.
Yes Considerations:
A. Occupancy Exposure – High?
B. Level of Fire Protection –
Low/None?
No C. Interdependency – High?
Public Fire Response D. Values of Building,
Capable of Responding Equipment, Inventory – High?
within 15 Minutes?
Yes
No
Incipient Fire Brigade
Recommended
Fire Prevention and Protection - Chapter 2
Occupancy Specific Protection
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1.0 PURPOSE
This chapter provides fire prevention and protection standards and additional
information for the most common occupancies found within General Motors
facilities.
2.0 SCOPE
This chapter is applicable to all GM managed facilities globally. Applicable local

regulations may supersede the GM standards.
3.0 STANDARDS
Sprinkler protection requirements for the occupancies identified herein are

summarized in Table 3.0-a.
Table 3.0-a
Recommended protection features for General Motors owned or leased facilities

of 100,001-350,000 ft2 (9290-32516 m2) are summarized in Table 3.0-b.
Table 3.0-b
Recommended protection features for General Motors owned or leased facilities

of 100,000 ft2 (9290 m2) or less are summarized in Table 3.0-c.
Table 3.0-c
3.1 General Assembly
3.1.1 Associated Hazards
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3.1.1.1 Fluid Fill
Install and protect fluid Filling Operations in accordance with Chapter 3, Section
3.4.
3.1.1.2 Dynamic Vehicle Test
Provide sprinkler protection for pits, exhaust ductwork and enclosures associated
with DVT operations.
3.1.1.3 Final Repair Paint Spray Operations
Protection information and details are available in the Global Paint & Polymers
Center Bill of Process – 34950.D.
34950D Fire
Protection GTR_3.pdf
3.1.1.4 Material Storage
Arrange and protect storage in support of the assembly operations in accordance

with Chapter 3, Section 3.6.
3.1.2 Sprinkler Protection
Install sprinkler protection throughout the facility, designed to provide a minimum

density of 0.40 gpm/ft2 (16.4 lpm/m2) over any including the most remote 4,000
ft2 (372 m2) area of application. This design density is considered adequate to
protect typical storage not exceeding 15 ft (4.6m) in height, arranged in piles not
exceeding 1000 ft2 (93 m2) with 8 ft (2.4 m) minimum aisles. Protect storage of
plastic materials in accordance with Section 3.6.
Storage arrangements beyond the above stated parameters and in areas where
extensive screen guard is installed, require a sprinkler density of 0.60 gpm/ft2
(24.4 lpm/m2) over any and the most remote 3,000 ft2 (279 m2) area of
application.
3.2 Paint Shop Operations
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Additional information and details are available in the Global Paint & Polymers
Center Bill of Process - 34950.D.
3.2.1 General
Prohibit smoking in all paint operation areas.
Do not permit Hot Work, such as cutting or welding, in paint operation areas
unless approval is given by a security supervisor. If Hot Work is required, ensure
it complies with Chapter 1, Section 3.4 of this manual. Additional information is
available on the GM Global Security Fire Prevention & Protection website, Fire
Guidelines web page, FPG-28 Hot Work - Cutting, Welding, and the Allied
Processes.
Do not store, dispense or process flammable materials below grade level.
3.2.2 Handling and Dispensing of Paint Materials
Do not use compressed air to pressurize containers or piping to facilitate transfer

of paint materials or flushing solvents. Only inert gas may be used to pressurize
containers for the transfer flammable liquids or liquids that are heated above their
flashpoints.
Provide properly grounded drip pans under all faucets. Also provide static
bonding between containers during transfer operations.
Install static grounding devices on any floor or platform where drums or other
containers are filled or emptied.
Ensure Class I and II liquids used in cleaning operations are in listed safety
containers. Ensure the ventilation system and all fire protection systems for the
spray booth remain on during cleaning operations. Limit cleaning operations to
not more than one gallon of flammable or combustible liquid for each cleaning
operation. Properly ground all equipment and personnel used in pressurized
spray cleaning operations.
3.2.3 Storage Rooms
3.2.3.1 General
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Provide storage rooms for paint materials that cannot be safely contained in
circulating and mixing systems or that cannot be properly stored elsewhere in the
plant.
If a storage room is used for opening totes or containers, agitating, mixing,

dispensing or other operations that may evolve vapors, apply the provisions of
Section 3.2.5 Dispensing and Mixing Rooms.
Isolate storage rooms from work or warehouse areas by firewalls with a minimum
three-hour rating. Ensure walls dividing paint storage from paint mix areas have
a minimum rating of two hours. Maintain the integrity of fire walls or fire barrier
partitions by airtight filling of any abandoned or partially used openings to the full
wall thickness with materials having the same fire resistance rating as the wall.
Provide heat and smoke venting.
Prohibit power operated trucks within storage rooms, unless they are listed or
approved battery powered units for hazardous areas. Equivalent requirements
may be considered upon acceptance of the authority having jurisdiction.
3.2.3.2 Heating and Ventilation
Provide continuous mechanical exhaust ventilation from storage rooms to

prevent accumulation of flammable vapors in excess of 25% of the lower
flammable limit.
3.2.3.3 Fire Protection
Protect all storage rooms with a wet pipe hydraulically designed sprinkler system
that is capable of discharging 0.60 gpm/ft2 (24.4 L/min/m2) for any and the most
remote 3,000 ft2 (279 m2) area of application.
Provide in-rack sprinkler protection for storage of drums in racks
Provide manual pull fire alarm devices located outside of and adjacent to
pedestrian doorways of the storage room.
3.2.4 Dispensing and Mixing Rooms
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3.2.4.1 General
Isolate dispensing and mixing rooms from work or warehouse areas by firewalls
with a minimum three-hour rating.
Ensure walls dividing paint mix from paint storage areas have a minimum rating
of two hours.
Install damage limiting construction on the exposed wall between the dispensing
and main plant area on a minimum designed basis of 100 PSF (488-kg / m2)
blast resistances.
Maintain the integrity of the fire wall or fire barrier partitions by airtight filling of
any abandoned or partially used openings to the full wall thickness with materials
having the same fire resistance rating as the wall.
Provide explosion relief venting.
Install smoke and heat venting.
Prohibit power operated trucks within mixing and dispensing rooms, unless they
are listed or approved battery powered units for hazardous areas. Equivalent
requirements may be considered upon acceptance of the authority having
jurisdiction
3.2.4.2 Floor Drainage and Containment
Ensure floors of dispensing and mixing rooms are concrete.
Where automatic sprinklers are the only form of protection, provide drainage in
accordance with Global Paint & Polymers Center Bill of Process - 34950.D.
3.2.4.3 Electrical
Install only electrical equipment classified for hazardous locations in dispensing

and mixing rooms.
3.2.4.4 Ventilation
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Provide continuous mechanical exhaust ventilation from dispensing and mixing

rooms to prevent accumulation of flammable vapors in excess of 25% of the
lower flammable limit.
Protect all dispensing and mixing rooms with a wet pipe hydraulically designed
sprinkler system that is capable of discharging 0.60 gpm/ft2 (24.4 L/min/m2) for
any and the most remote 3,000 ft2 (279 m2) area of application..
Provide manual pull fire alarm devices located outside of and adjacent to
pedestrian doorways of the storage room.
3.2.5 Fan Rooms and Penthouse
Ensure sprinkler protection is part of the building system. Design the sprinkler
system to provide 0.30 gpm/ft2 (12.2 L/min/m2) over 3000 ft.2 (279 m2).
Install dry-pipe systems where piping is subject to freezing.
3.2.6 Process Enclosures
Protect all process enclosures with a wet pipe sprinkler system hydraulically
designed for 0.30 gpm /ft2 (12.2 L/min/m2) over 3,000 ft2 (279 m2) or the area of
the enclosure whichever is less.
3.2.7 Powder Coating
3.2.7.1 General
Install, operate and maintain powder coating processes in accordance with

Global Paint & Polymers Center Bill of Process-34950.D.
Perform powder spraying only in booths provided for that purpose.
Do not locate spray booths in basements or other below grade rooms.
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Construct booths of non-combustible material, and equip with devices and

facilities for cleaning, ventilating, lighting, maintenance, fire protection and safety.
Provide door exits in tunnel type booths on each side of the conveyor line,
spaced not more than 75-ft. (15-m) apart. Provide exits at each end of the booth.
3.2.7.2 Electrical
Install only electrical equipment classified for hazardous locations within or

adjacent to spray areas and spray booths.
3.2.7.3 Fire Protection/General
Protect the powder spray booth, robot rail enclosures, equipment closets and
non-automated zones with a pre-action sprinkler system.
Design and locate sprinkler systems to provide an effective distribution of water

throughout the entire process.
Design sprinklers to provide a density of 0.35 gpm/ ft2 (14.2 L/min/m2) for the
entire booth area.
Provide the necessary signaling, alarms, interlocks, etc., as indicated on Diagram

No.4.
Diagram 4.xls
Ensure the automatic sprinkler system for each spray booth, including its
connecting exhaust system, is controlled by an accessibly located, plainly
identified valve.
Protect the bell station side cabinets with an automatic wet sprinkler system.
Protect interior exhaust ducts subject to powder residue with wet pipe sprinklers.
Interior supply plenums do not require sprinkler protection unless combustible
filters are utilized. Design the sprinkler system for a maximum of 40 heads
flowing 30 gpm (113 L/m) per head. Install heads not more than 12-ft. (3.7-m)
apart. Provide openings for access to each sprinkler head.
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Use only open head manual systems for exterior exhaust plenums and ducts.
Design the sprinkler system for a maximum of 40 heads flowing 30 gpm (113
L/m) per head.
Protect the powder storage room with an automatic wet sprinkler system. Design
the sprinkler system to provide a density of 0.30 gpm/ ft2 (12.2 L/min/m2) for the
affected area.
If a remote collector is used, ensure fire dampers in the ductwork close to

interrupt airflow from the booth to the collector in the event of a fire incident within
the booth.
3.2.8 Liquid Spray Finishing
3.2.8.1 General
Do not locate spray booths in basements or other below-grade rooms.
Construct booths of non-combustible materials. Aluminum construction is

prohibited. Ensure side machine and cat-trac enclosures, utilized in “clean wall”
designs, are also noncombustible.
Protect all spray booths; flash off areas, side cabinets, exhaust systems and cat-
trac enclosures with a wet pipe automatic sprinkler system.
Design and locate sprinkler systems to provide an effective distribution of water

throughout the entire process.
Design the sprinkler systems to deliver a density of 0.35 gpm/ ft2 (14.2 L/min/m2)
for the most remote, 3,000 ft2 (279 -m2) or the entire booth, whichever is less.
Where solvent-based or self sustaining water-based paints are used, provide

deluge water spray sprinkler protection for the booth interior of each spray zone
(each zone individually controlled). Design the system to provide a density of
0.60 gpm/ ft2 (24 L/min/m2). Ensure detection is by single frequency, infrared
flame detectors.
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Ensure the automatic sprinkler system for each spray booth, including its
connecting exhaust system, is controlled by an accessibly located, plainly
identified valve.
Protect interior exhaust ducts, eliminators, plenums and tunnels with wet pipe
sprinklers. Design the sprinkler system for a maximum of 40 heads flowing 30
gpm (113 L/m) per head. Install heads not more than 12-ft. (3.7-m) apart.
Provide openings for access to each sprinkler head. Design the system to limit
the number of sprinklers controlled by sub-valves in order to meet water supply
capabilities.
For all new or renovated paint spray booths, ensure the pipe and hangers
exposed to the exhaust stream are stainless steel.
Provide open head manual systems for exterior exhaust plenums, stacks, and
ducts. Design the sprinkler system for a maximum of 40 heads flowing 30 gpm
(113 L/m) per head. For water wash type booths, perform a biannual inspection
of these systems. Replace obstructed sprinkler heads as needed.
Where exhaust air is re-circulated to booth supply, apply the provisions of the
Global Paint & Polymers Center Bill of Process 34950.D.
Depending upon the type of paint application and paints employed, Logic
Diagrams Nos. 1, 2, or 3 must be applied for the protection features and
associated interlocks.
Diagram 1.xls Diagram 2.xls Diagram 3.xls
3.2.9 Dosing Pumps and Color Changers
Protect dosing pumps and color changer enclosures with sprinklers fed by the
booth system.
3.2.10 Drying Equipment
3.2.10.1 General
Locate ovens and heaters at or above grade level.
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Locate oven heaters, other than those of steam type, a minimum of 20-ft. (6.1-m)
away from spray booths and paint storage and mix rooms.
Design and locate ovens to provide adequate space for proper functioning of
explosion vents, fire fighting accessibility, inspection, and maintenance.
Thoroughly evaluate the need for proper explosion relief of the drying chamber
and/or heating source with respect to the style of firing (indirect versus direct)
and the liberation of flammable vapors that may accumulate and/or approach
25% of the lower explosive limit if ventilation within the unit fails.
Construct ovens to minimize the transmission of solvent vapors through the inner
shell and the subsequent condensation of these vapors in the insulation section
between the inner and outer shells.
Equip ovens with access doors or openings and lights in adequate number and
size to permit inspection, maintenance, and fire fighting access. Ensure
distances between access doors and/or openings do not exceed 100-ft. (33-m).
3.2.10.2 Heating and Ventilating
Ensure oven ducts, insulation and covering materials are constructed of non-
combustible materials.
Design stacks to prevent entry of exhaust into the facility.
Mechanically exhaust ovens to the outside atmosphere with dedicated fans.

Recirculation fans and spill exhaust systems are not permitted.
Provide a purge cycle consisting of at least four complete air changes of the oven
and heating chamber(s) prior to light-off of the oven. Prove this air purge by fan
motor/starter interlocks and airflow or differential pressure switches.
In continuous process ovens, ensure the rate of ventilation is adequate to assure

the concentration of vapors is less than 25% of the lower explosive limit. When
production load is increased, increase the exhaust capacity accordingly.
Arrange the ovens so that in the event of an unscheduled shutdown of a single

heater zone, the entire oven will not require shutdown and purge. Ensure the
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arrangement includes dampers to allow purge of the affected heating chamber

and zone and the ability to bring the zone back on line.
A complete oven re-purge is required when one of the following conditions

occurs:
Failure of the oven exhaust fan
or,
Loss of more than one heater zone
3.2.10.3 Sprinkler Protection
Provide automatic sprinkler protection throughout the oven processing

combustible products.
Where sprinkler protection is required, with a hydraulically design a closed head

sprinkler system that is capable of discharging 0.35 gpm/ ft2 (14.2 L/min/m2) for
any and the most remote 4,000 ft2 (372 m2) or the total area of the oven,
whichever is less.
3.2.10.4 Heated Flash Zones
Classify heated flash zones as ovens, and install protection features accordingly.
Modular Applications without Doors and In-Line Applications
Separate spraying operations from heated flash infrared heating elements

by at least a 10-ft. (3.1-m) silhouetted vestibule.
Separate spraying operations from heated flash convection zones by at

least a 3-ft. (1-m) silhouetted vestibule.
Provide sprinkler protection for all exhaust systems including silhouetted

vestibules, except for heated flash exhaust ducts independently ducted directly to
atmosphere. On recirculated exhaust from the heated flash, provide sprinkler
protection within the exhaust duct up to and just beyond the first filter bank.
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Do not connect exhaust ducts from heated flash zone and spray operations
unless they are sprinkler protected and approved for the specific application.
Ensure all manifolding of exhaust ducts is downstream of exhaust fans. Ninety-
degree connections are not permitted.
Provide a closed head, wet pipe sprinkler system throughout the heated flash
zone and silhouetted vestibules on a hydraulically designed basis of 0.35 gpm/ ft2
(14.2 L/min/m2).
3.2.11 Canopies, Tunnels and Enclosures
See Global Paint & Polymers Center Bill of Process 34950.D for details with
respect to these installations.
3.2.12 Spot Reprocessing
Perform paint spraying only in booths provided for that purpose. See Global
Paint & Polymers Center Bill of Process 34950.D for details with respect to these
installations.
3.2.13 Abatement and Associated Equipment
Environmental requirements for air purification may necessitate the need to

abate exhaust air from painting operations or ovens. See Global Paint &
Polymers Center Bill of Process 34950.D for details with respect to these
installations.
3.3 Body Shop

density of 0.20 gpm/ft2 (8 lpm/m2) over any and including the most remote 2,000
ft2 (186 m2 ) area of application. This design density is considered adequate to
protect storage not exceeding 5 ft (1.5 m) in height, arranged in piles not
exceeding 500 ft2 (46 m2). Storage arrangements in excess of the stated
maximum must be reviewed by Global Security for appropriate increases in
sprinkler protection.
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3.4 Machining
3.4.1 Machine Enclosures
3.4.1.1 Machine Enclosures
Protect exhaust ductwork and collection systems associated with machining

operations in accordance with Chapter 3, Section 3.5.
Many machine enclosures contain oil lubrication systems, oil coolants, and/or
hydraulic oil systems. The enclosure prevents the ceiling level sprinkler system
discharge from reaching these hazards. Provide protection within the machine
enclosure if any of the following conditions exist:
Operations using water soluble coolant with an enclosure size greater

than 100 ft2 (9.3 m2). Enclosure size may exceed 100 ft2 (9.3 m2) if the
operation is continuously bathed in coolant.
Operations using mineral oil coolant with an enclosure size greater than
50 ft2 (4.6 m2).
The enclosure is constructed of any material other than listed plastic-

insulated panels, fiberglass/mineral fiber-insulated panels, or non-
insulated metal panels.
A single source/critical production operation is involved, without make-up

capacity.
Looped exhaust system designs are employed.
3.4.1.2 Material Storage
Protect material storage in support of the assembly operations in accordance

with Chapter 3, Section 3.6.
3.4.2 Protection
3.4.2.1 Sprinkler Protection
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density of 0.30 gpm/ft2 (12.2 lpm.m2) over any and including the most remote
4,000 ft2 (372 m2) area of application. This design density is considered
adequate for the protection of storage not exceeding 10 ft (3 m) in height, and in
piles not exceeding 500 ft2 (46 m2).
Storage arrangements beyond the above stated parameters require either

additional local protection or a ceiling sprinkler density of 0.60 gpm/ft2 (24.4
lpm/m2) over any and the most remote 3,000 ft2 (279 m2) area of application.
Insulation Material
Guidance for the selection of insulation materials for machine enclosures can be
found in the Appendix.
3.5 Stamping
Install sprinkler protection for the first floor level of contiguous stamping
operations, if required, in accordance with the local Authority Having Jurisdiction.
Install sprinkler protection throughout the basement of the facility at a minimum

density of 0.30 gpm/ft2 (12.2 lpm.m2) over any and the most remote 3,000 ft2
(279 m2) area of application. This approach is based on the presence of oil
storage and transfer systems for the press lubrication systems. Limit storage in
these areas to 10 ft (3 m) in height and arrange in piles not exceeding 500 ft2 (46
m2) piles.
3.6 Warehousing
This Section applies to building areas dedicated to the storage of combustible

commodities, expanded and non-expanded plastics (exposed and non-exposed),
and rubber tires. This storage may be in bulk, palletized, portable rack or fixed
rack arrangements. This Section does not apply to storage which is incidental to
the primary area operations. For storage within non-warehousing occupancies,
refer to Chapter 3, Section 3.6.
3.6.1 Separation
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Separate storage areas from manufacturing or assembly areas by detachment,

fire walls, fire barriers, or deep draft curtains, depending upon the degree of
hazard.
3.6.2 Control of Hazards
3.6.2.1 Powered Industrial Trucks
Prohibit the refueling or repair of powered industrial trucks or stackers within 35 ft

(10.7 m) of any storage rack or pile.
3.6.2.2 Smoking
Prohibit smoking in warehousing areas.
3.6.3 Protection Requirements
Protection requirements for storage facilities of less than 500,000 ft2 (46,452 m2)
may be less than those specified elsewhere in this manual. Use Table 3.6.3-a to
determine the appropriate reference table for protection requirements.
Table 3.6.3-a
Reference Tables 3.6.3-b and 3.6.3-c
Table 3.6.3-b Table 3.6.3-c
3.6.3.1 Smoke Detection
Provide smoke detection for storage of exposed expanded plastics or rubber

tires.
3.6.3.2 Manual Fire Suppression
Locate interior hose stations equipped with 100 ft. (30 m) of 1-1/2 inch
(38 mm) hose and a combination nozzle or acceptable equivalent so that any
point in the storage area can be reached by two hose streams. Add 750 gpm
(2,839 L/min) to the water demand for hose streams.
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Provide portable extinguishers in all storage areas, as specified in National Fire

Protection Association (NFPA) Standard 10 - Portable Fire Extinguishers, or
equivalent local code or regulation.
3.6.3.3 Fixed Automatic Fire Suppression
Provide automatic sprinkler protection at the ceiling, in any new or renovated

dedicated storage area, designed to provide a minimum density of 0.3 gpm/ft2
(12.2 L/min/m2) over any and the most remote 4,000 ft2 (372 m2) area of
application.
Fixed-Rack Storage
Protect fixed-rack storage in accordance with local recognized standards.
It may be necessary to add one additional level of in-rack sprinklers for rack
storage of exposed Group A plastic between 10 ft (3.1 m) and 25 ft (7.6 m).
Consult Global Security.
Bulk, Palletized and Portable Rack Storage
Protect bulk, palletized and portable rack storage of expanded Group A plastics
in accordance with Table 3.6.3.3-a.
table 3.6.3.3.a.docx
Protect bulk, palletized and portable rack storage of non-expanded Group A

plastics in accordance with Table 3.6.3.3-b.
table 3.6.3.3.b.docx
Where the ceiling sprinkler density is less than 0.30 gpm/ft2 (12.2 L/min/m2) over
any and the most remote 4,000 ft2 (372 m2) area of application, limit storage
heights to 5 ft (1.5 m) and pile sizes to 500 ft2 (46 m2).
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Protect Class 1 through 4 commodities in accordance with local recognized

standards, but to a density of not less than 0.3 gpm/ft2 (12.2 L/min/m2) over any
and the most remote 4,000 ft2 (372 m2) area of application. Do not use areas
with flat roof deck heights in excess of 35 ft. (10.7m) for bulk, palletized or
portable rack storage.
Specific Application Sprinklers
Specific application sprinklers are an acceptable alternative to the sprinkler

densities in tables 3.6.3.3-a and 3.6.3.3-b, that are based on the use of standard
spray sprinklers.
Specific application sprinklers are to be used only in areas that are entirely
dedicated to storage, and must not be installed in areas which may be converted
into manufacturing occupancies in the future.
Specific Application Sprinklers must only be used with wet pipe systems and
must be installed strictly in accordance with their listing/approval (e.g., building
height, storage height, clearance, etc.).
Include 250 gpm (946 Lpm) hose allowance in water supply calculations for
systems using specific application sprinklers.
Where quick response sprinklers are installed (such as ESFR), separate these
sprinkler systems from other sprinkler systems with a minimum 3 ft (1 m) draft
curtain and a minimum 8 ft (2.4 m) clear aisle.
Where specific application sprinklers are used, follow the maximum pile sizes
indicated in Table 3.6.3.3-c.
table 3.6.3.3.c.docx
3.7 Offices
Provide sprinkler protection in all new and existing administration, office,

engineering and laboratory buildings in accordance with Table 3.0-a.
4.0 RECORDS – N/A
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5.0 REFERENCES (ADD NFPA AS APPLICABLE)
General Motors References

Global Paint & Polymers Center Bill of Process – 34950.D
National Fire Protection Association Standards

10 Portable Fire Extinguishers
13 Installation of Sprinkler Systems
30 Flammable and Combustible Liquids Code
33 Spray Application Using Flammable and Combustible
Materials
34 Dipping and Coating Processes Using Flammable and
Combustible Liquids
70 National Electrical Code
77 Static Electricity
86 Ovens and Furnaces
91 Exhaust Systems for Conveying of Vapors, Gases, Mists, and
Noncombustible Particulate Solids
505 Powered Industrial Trucks

08/17/2009 2 Updated Fire Guidelines
09/29/2009 3 Revised Technical
Contact
08/04/2010 4 Revise Rack Storage
Protection Requirements
01/21/2011 5 Revise Table 3.0a
7.0 DEFINITIONS
Specific Application Sprinkler - A type of spray sprinkler listed at a minimum

operating pressure with a specific number of operating sprinklers for a given
protection scheme.
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8.0 APPENDIX

8.3.1.1.2 General Assembly - Dynamic Vehicle Test
Automatic sprinkler protection for pits should be hydraulically calculated to deliver

a density of 0.30 gpm/ft2 (12.2 lpm/m2) for the entire area.
Automatic sprinkler protection for the dynamic vehicle test exhaust system
should be designed based on 20 sprinkler heads operating @ 30 psi, minimum
start pressure.
8.3.1.2.1 Sprinkler Protection Beneath Screen Guard
Based on actual fire testing results, the following fire protection arrangements are
recommended for areas where screen guarding is present:
Recommendation 1: If horizontal obstructions are present above the screen

guard (e.g., a conveyed vehicle body): Provide sprinklers under the screen
guard in accordance with this manual, based on the storage height and
commodity.
OR
Recommendation 2: If vertical obstructions are present above screen guard

(e.g., hanging, conveyed vehicle components, i.e. hoods, doors, etc.) or no
obstructions above screen guard (i.e., empty return conveyors), protect as
follows:
Screen guard with no storage below, and minimum 0.30 gpm/ft2 sprinkler
system at the ceiling: No additional sprinkler protection required.
Screen guard with maximum 10 ft. high storage below:
o 0.30 gpm/ft2 sprinkler system at the ceiling and appropriate sprinklers

under the screen guard.
1 Appendix
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OR
o 0.60 gpm/ft2 sprinkler system at the ceiling; no sprinklers required

under the screen guard.
Screen guard with >10 ft. high storage below: Provide sprinklers under
the screen guard in accordance with the policies established in this
manual.
In all cases the screen guard with at least a nominal 2 in. x. 4 in. (51 mm x
102 mm) opening should not be blocked by materials, cardboard, plastic
sheets, etc.
8.3.2.1 Paint Shop Operations - General
Paints and related materials referred to include: solvents, thinners, metallics,

primers, high solids enamels, adhesives, sealers, and other similar materials. In
general, most ELPO and phosphate materials are considered to be non-
combustible and not subject to the requirements of this Chapter.
Existing painting operations that do not completely conform to the requirements

contained in this Section should be upgraded where the discrepancies are
recognized hazards to life or property or where they conflict with enforceable
governmental regulations. Potential deviations from this standard for any new or
modified paint systems should be reviewed and approved in advance by Global
Paint & Polymers Center and Global Security.
The properties of all materials involved in painting operations, including the

cleaning and other processing of parts prior to painting, should be carefully
investigated and should not be used until they are approved by the Hazardous
Materials Control Committee at the local facility. The current edition of
"Dangerous Properties of Materials", published by Reinhold Publishing
Corporation, New York, provides a source for hazard-analysis information for
more than 10,000 common industrial materials.
8.3.2.2 Handling and Dispensing of Paint Materials
Storage and/or dispensing of paint materials within the plant, but outside paint
storage, mixing rooms or storage cabinets should be limited to the amount
prescribed in NFPA 33 - Spray Application Using Flammable and Combustible
2 Appendix
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Materials. See STORAGE ROOMS, DISPENSING AND MIXING ROOMS, and

LIQUID SPRAY FINISHING for amounts that exceed those described.
Cabinets used to store flammable materials should conform to the requirements

of NFPA 30 - Flammable and Combustible Liquids Code.
Paint materials should be conveyed in approved containers that are undamaged

and closed or sealed to prevent spillage. “Approved” containers should be of the
type listed or approved by Underwriters Laboratory Inc., FM Global, U.S.
Department of Transportation (DOT) or equivalent governmental regulatory
agency.
The following should be considered with regard to containers and portable tanks:
All paint materials should be received only in approved containers,

properly labeled to clearly indicate contents. A positive method of
identifying drums should be established as prescribed by the Hazardous
Materials Communication Program guidelines to clearly indicate contents
and to serve as a safeguard in handling.
Portable tanks should be provided with emergency relief venting.
If a replacement cover is installed on a portable tank, this cover should be

provided with an emergency relief vent.
Containers and portable tanks should not be stored in excess of the

maximum heights and areas prescribed in NFPA 30 - Storage of
Flammable and Combustible Liquids.
Approved drum pumps are recommended for handling small quantities of paint
materials.
Valves or faucets used for dispensing or transferring paint materials should be of

the approved, self-closing type so that the flow of liquid stops automatically when
the operator's hand is removed at the point of draw-off.
All containers and portable tanks, when being emptied or filled should be visibly
grounded and bonded. Racks used in storing paint materials should be
grounded.
3 Appendix
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Waste liquids, dirty rags, and other disposable media should be placed in
approved safety containers. These materials should be removed daily and
disposed of in a safe manner.
After using or emptying containers, all bungs and shut-offs should be
immediately replaced or closed. Empty pails, cans, and barrels are dangerous
due to the presence of explosive vapors. After emptying, containers should be
removed immediately to an approved storage area. Drums that have been used
for transporting solvents should be identified when emptied and to be returned.
Employees supervising or performing any paint operations should be familiar with

the hazards involved and practices necessary to minimize fire, explosion and
health hazards.
8.3.2.3.1 Storage Rooms
Explosion venting is not needed unless local code requires venting, there is
dispensing of flammable liquids or the mix room and storage rooms are not
adequately separated with normally closed fire doors.
Production Welding operations should not be permitted to be located within 35-ft.

(10.7-m) of openings to storage rooms.
Housekeeping and Maintenance:
All abandoned piping and wiring should be removed promptly.
Paint spills should be cleaned immediately.
Mopping the floors with flammable liquids should be prohibited.
8.3.2.4.1 Dispensing and Mixing Rooms
Dispensing and mixing rooms should be provided for paint mixing and dispensing
operations that are not permitted to be located elsewhere in the plant due to size
of the room and quantity of paint material as prescribed by Chapter 8, NFPA 33 -
Spray Application Using Flammable and Combustible Materials.
Production welding operations should not be permitted to be located within 35-ft.

(10.7-m) of openings to dispensing and mixing rooms.
4 Appendix
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An emergency shutoff switch, to stop the paint mix and circulation systems,
should be installed outside the pedestrian doors.
All equipment (including insulated devices such as agitator covers, etc.), paint
material lines, racks, and containers and portable tanks should be visibly
grounded.
Circulating thinners and paint lines should be of steel, or other material having
comparable properties of resistance to heat and physical damage.
Housekeeping and Maintenance
All abandoned piping and wiring should be removed promptly.
Paint spills should be cleaned immediately.
Mopping the floors with flammable liquids should be prohibited.
8.3.2.6 Process Enclosures
This section includes enclosures for the following operations: Sanding, Prep,
Blow-off, Feather Dusters (EMU), and Solvent wipe
Automatic sprinkler piping for each enclosure should be controlled by indicating

type valves located at an accessible work level.
Exhaust systems do not require sprinkler protection.
Enclosure sprinklers should be supplied from plant ceiling (building)

sprinklers.
8.3.2.7 Powder Coating
Production welding operations should not be permitted within spray booths and
spray finishing areas and should not be located within 35-ft. (10.7-m) of openings
to spray booths or spray finishing areas.
Cutting or welding (Hot Work) or open flame (e.g. soldering) should not be
permitted within spray booths or spray finishing areas. All alternative work
methods should be considered. Prior to any welding, the booth should be free of
5 Appendix
Level
residue, and a safe operating plan should be developed. See Chapter 1, Section
3.4 for further information.
8.3.2.7.2 Electrical
The spray booth and all equipment, such as piping, conduit, lighting, fixtures,
motors, and switches installed in conjunction with same should be grounded.
Lighting fixtures in the spray booth should not be located where they are
continually and directly exposed to air laden with paint powder. Flush mounted
fixtures should be listed or approved dust-tight type with a high stress or wire
glass lens.
If lighting fixtures are located entirely inside the spray booth, they should be of
the explosion-proof type.
Re-lamping of fixtures should be conducted from outside the booth unless the
fixtures are listed Class II Division 1 or 2 equipment. Maintenance operations in
the booths should utilize rated electrical equipment. Portable units, cabling, and
receptacles should be listed for Class II, Division 1, Group G locations and
should not remain in the booth during spraying operations.
Ventilation and Collection Equipment
Ventilating equipment should provide the volume and velocity of air necessary to
contain and remove powder overspray.
Ample access doors should be provided in all ducts, stacks, and exhaust tunnels
for the purpose of cleaning, repairing, inspection and replacing of sprinklers and
manual fire fighting,
Non-deposited air-suspended powders should be safely removed from the spray

operation to a powder recovery system. It is recommended that the powder
collection system be a cartridge type collector located below the booth grating. If
a remote collection system is used, sufficient airflow should be provided to
maintain the exhaust duct at a powder concentration that will not exceed one-half
of the minimum explosive concentration (MEC) of the powder in use.
6 Appendix
Level
Any enclosures of a powder coating operation (booth, collection system, etc.)

that are effectively “tight” enclosures should be provided with adequate blow-out
openings to safely relieve internal pressure in case of mixture ignition.
Air exhausted from the recovery system of a powder operation should not be re-
circulated as input air for that operation unless:
The particulate composition of the exhaust air has been returned to an

acceptable safe level by the use of high-efficiency filters, and
The installed equipment continuously monitors the exhausted air to signal

the operator and to automatically shut down the operation in the event the
particulate removal equipment fails to maintain the air in this condition.
8.3.2.7.3 Sprinkler Protection
Existing booths having extra hazard sprinkler protection need not be revised.
The automatic zones of the powder spray booth should utilize single frequency
infrared flame detectors. The robot rail enclosures, equipment closets, and any
non-automated areas protected by the preaction should utilize rate-compensated
thermal detectors. These thermal detectors should be rated at 140 deg. F (60
C).
Stacks over 6-ft. (1.8-m) in diameter or width may require sprinklers installed on
an individually engineered basis with approval by the authority having jurisdiction.
Global Security should be contacted for review. The system should be designed
to limit the number of sprinklers controlled by sub-valves in order to meet water
supply capabilities.
Booth sprinklers should be supplied independently of plant ceiling sprinklers. The

supply should encompass a two-way feed arrangement from the yard main with
the risers and sectional control valves arranged to minimize impairment potential.
A separate water flow alarm should be installed for each spray booth and
connected to the plant proprietary alarm console.
Sprinkler heads within spray booths subject to powder overspray should be

protected from spray residue by lightweight polyethylene bags having a thickness
of 0.003 (0.08-mm) inches or less. These should be changed frequently.
7 Appendix
Level
Powder collection systems should be equipped with adequate explosion relief.
8.3.2.8 Liquid Spray Finishing
Circulating thinner and paint lines located outside the booth enclosure should be
of steel or other material having comparable properties of resistance to heat and
physical damage.
Glass panels in booth walls are not recommended. If viewing windows are
necessary, they should be of wired glass and of limited dimensions.
Door exits should be provided in tunnel type booths on each side of the conveyor
line. Exits should be provided at each end and spaced along each side not more
than 75-ft. (23-m) apart.
Production welding operations should not be permitted to be located within 35-ft.

(10.7-m) of openings to spray booths or spray finishing areas.
Electrical
Electrical equipment in spray areas and spray booths should conform to NFPA
70 - National Electric Code for Class I, Division 1, (Zone 1) Group D locations, or
local/regional equivalent.
The spray booth and all equipment, such as piping, conduit, lighting, fixtures,
motors, and switches installed in conjunction with same should be grounded.
Lighting fixtures in the spray booth should not be located where they are
continually and directly exposed to air laden with paint solvents. Flush mounted
fixtures should be listed vapor-tight type with a high stress or wire glass lens. If
lighting fixtures are located entirely inside the spray booth, they should be of the
explosion-proof type.
Re-lamping of fixtures should be conducted from outside the booth unless the
fixtures are listed Class I Division 1 or 2 (Zone 1 or 2).
The use of portable hand lamps or fixtures on movable stands in spray booths
should be avoided except where necessary for cleaning and other maintenance
operations. Such portable units, cabling, and receptacles should be listed for
8 Appendix
Level
Class I, Division 2 (Zone 2), Group D locations and should not remain in the
booth during spraying operations.
All electrical equipment within or adjacent to a spray booth should conform to

NFPA 33 - Spray Application Using Flammable and Combustible Materials and
NFPA 70 - National Electric Code.
Ventilation
Ventilating equipment should provide the volume and velocity of air

necessary to contain and remove vapor and over-spray.
Ample access doors should be provided in all ducts, stacks, and exhaust
tunnels for the purpose of cleaning, repairing, inspection, replacing of
sprinklers and fire fighting.
Scrapings and debris contaminated with paint residue should be removed

promptly from the facility and disposed of in a safe manner.
All spray equipment should be appropriately maintained.
Materials and non-associated equipment should not be located and/or stored

within 3-ft. (1-m) of the booth.
Maintenance operations in the booths should utilize rated electrical equipment.

Portable units, cabling and receptacles should be listed for Class I, Division 1
(Zone 1), Group D locations and should not remain in the booth during spraying
operations.
Class I and II liquids used in cleaning operations should be in listed safety

containers. The ventilation system and all fire protection systems for the spray
booth should remain on during cleaning operations. Cleaning operations should
be limited to not more than one gallon of flammable or combustible liquid for
each cleaning operation. Handling of the liquids should be in accordance with
Chapter 8 of NFPA 33 - Spray Application Using Flammable or Combustible
Liquids. All equipment and personnel should be properly grounded for
pressurized spray cleaning operations.
9 Appendix
Level
8.3.2.8.2 Fire Protection
Existing booths having extra hazard sprinkler protection need not be revised.
Interior supply plenums do not require sprinkler protection unless combustible

filters are utilized.
Central exhaust stacks over 6-ft. (1.8-m) in diameter or width may require
sprinklers installed on an individually engineered basis with approval by the
authority having jurisdiction. Global Security should be contacted for review.
If Robotic Nozzle washers are of an open top design, or otherwise significantly

exposed to the protection provided by the booth deluge and wet pipe sprinklers,
additional special protection is not required within the nozzle washers.
Booth sprinklers should be supplied independently of plant ceiling sprinklers. The

supply should encompass a two-way feed arrangement from the yard main with
the risers and sectional control valves arranged to minimize impairment potential.
A separate water flow alarm should be installed for each spray booth line and
connected to the plant proprietary alarm console.
Sprinkler heads within spray booths subject to paint overspray should be

protected from spray residue by lightweight paper bags or by polyethylene bags
having a thickness of 0.003inches (0.08mm) or less. These should be changed
frequently.
All paint and thinner supply circulating to the booth (including specialty and
satellite systems) should be shut down automatically on activation of the booth's
fire extinguishing system(s). For additional interlock details, see the appropriate
“Process Fire Protection Systems Logic Diagram”.
Emergency manual paint and thinner pump shut down stations should be
installed outside booths and arranged so that the unobstructed travel distance to
each stop switch is not over 75-ft. (23-m) from each booth exit. A local
visual/audible alarm should be provided at each stop station.
Where the circulating thinner lines are located above the booth's paint stations,
spring loaded check valves should be installed in the thinner supply line at the
drop point prior to any plastic tubing. In addition, a regular or spring-loaded check
10 Appendix
Level
valve should be installed in the return at the point that the tubing reconnects to
the hard piping.
Air supply, exhaust, and sludge water removal systems should remain
operational when the booth is in use, occupied for maintenance functions, or in
the event of a fire incident. Additionally, activation of the fire protection
equipment in the paint booth, ductwork, filter houses or adsorption equipment
should permit direct exhaust (to atmosphere) of the air in the paint process. Any
abatement equipment should be by-passed. The thermal oxidizer should remain
running.
Fire Protection Process Criteria for Existing Facilities with Approved Equipment
(Diagram No. 1):
The following are additional fire protection requirements for U.L. Listed and/or
F.M. approved robotic waterborne non-electrostatic, non-robotic, non-rotary
spray equipment installations, including: non-electrostatic (Manual and
Automatic); electrostatic (Manual and Automatic); and non-electrostatic approved
robotic (Waterborne/Solvent).
Signaling, alarms, interlocks, etc., should be as shown on Diagram No. 1.
Sprinklers, extended from the booth system, should be installed in cabinet

enclosures that contain color changers, paint and/or thinner lines,
including side cabinets for “clean wall” booth designs. Drainage for the
cabinets should be directed to the flood sheet with the exception of hose
retractor cabinets.
Existing Facilities outside Europe using Non-Approved Equipment (Diagram No.

2)
Additional Fire Protection Requirements for this section are intended for the on-
going maintenance and repair of systems currently in use outside of Europe (See
Diagram No.2).
Spray equipment includes: non-robotic electrostatic rotary atomizers; robotic

electrostatic rotary atomizers; robotic electrostatic non-rotary atomizers; and non-
approved robotic.
11 Appendix
Level
Sprinklers, extended from the booth system, should be installed in

cabinets, enclosures that contain color changers, paint and/or thinner
lines, including side cabinets for “clean wall” booth designs. Drainage for
the cabinets should be directed to the flood sheets with the exception of
hose retractor cabinets.
NOTE: THE FOLLOWING THREE ITEMS APPLY TO SOLVENT BASED

OR SELF-SUSTAINING WATER BASED PAINTS.
Existing installations with combination ultra-violet/infrared flame detectors

are satisfactory; however, when replacement of the detectors is required,
single frequency infrared flame detectors should be used. Deluge
actuation is by cross-zoned optical detectors. If protected zones are
adjacent to each other, it may be necessary to simultaneously discharge
systems for more than one zone.
If the color changer is exposed to the booth deluge system (i.e. open top)
carbon dioxide (CO2) is not required within the enclosure.
Carbon dioxide cylinders, deluge valves including trim and fire control
panels should be located outside the booth (same floor as booth operating
level).
All New Global Facilities (Diagram No. 3)
The following are additional fire protection requirements for new robotic and
rotary spray equipment installations:
Spray equipment includes: non-robotic electrostatic rotary atomizers; robotic

electrostatic rotary atomizers; robotic electrostatic non-rotary atomizers; non-
approved robotic.
Sprinklers, extended from the booth system, should be installed in

cabinets, enclosures that contain color changers, paint and/or thinner
lines, including side cabinets for “clean wall” booth designs. Drainage for
12 Appendix
Level
the cabinets should be directed to the flood sheet with the exception of
hose retractor cabinets.
NOTE: THE FOLLOWING FIVE ITEMS APPLY TO SOLVENT BASED OR

SELF-SUSTAINING WATER BASED PAINTS.
Carbon dioxide (CO2) flooding should be provided for each turbine

enclosure, color changer and side cabinet. The carbon dioxide (CO2)
concentration should be 34%, should be achieved within one minute, and
held for one minute. The Carbon dioxide (CO2) concentration should be
measured at the most remote point from the discharge nozzle. Detection
should be by listed and approved methods. The suggested method of
detection is fiber optics. CO2 is not required for the cat-trac enclosure
area when the cables for servomotors and electrostatic power are listed
for use with solvents in painting operations.
The activation of any one booth flame detector should cause a localized
interruption of the paint flow and an intermittent discharge of carbon
dioxide (CO2) (as long as the detector sees flame) through the paint
applicator. It is intended that this is the initial automatic fire protection
system to be activated in the spray booth. For timing sequence refer to
Diagram No.3.
Deluge water spray sprinkler protection should be provided for the booth
interior of each zone (each zone individually controlled). Design density
should be 0.60 gpm/ ft2 (24 L/min/m2). Detection should be by single
frequency, infrared flame detectors. Existing installations with combination
ultra-violet/infrared flame detectors are satisfactory; however, when
replacement of the detectors is required, single frequency infrared flame
detectors should be used. Deluge actuation is by cross-zoned optical
detectors after a 15-second delay has elapsed. If protected zones are
adjacent to each other, it may be necessary to simultaneously discharge
systems for more than one zone.
If the color changer is exposed to the booth deluge system (i.e. open top)
carbon dioxide (CO2) is not required within the enclosure.
Carbon dioxide (CO2) cylinders, deluge valves including trim and fire
control panels should be located outside the booth (same floor as booth
operating level).
13 Appendix
Level
8.3.2.10 Drying Equipment
Ovens and heaters should be installed in accordance with NFPA 86 - Standards

for Ovens and Furnaces, or equivalent standard.
All oven areas should be well posted with "No Smoking" signs.
Cutting and welding should not be permitted within ovens. Cutting or welding
within ovens should be in accordance with Chapter 1, Section 3.4. Approval is
required from a security supervisor.
Ovens should be periodically inspected internally during down times to insure

that the accumulation of residues is not excessive. Generally, accumulations add
a significant combustible load to the drying apparatus and should be removed.
Scrapings and debris contaminated with paint residue should be removed

promptly from the facility and disposed of in a safe manner.
8.3.2.10.3 Fire Protection
It may be necessary, based on emergency cool-down procedures or building

ventilation system failures, to raise the operating temperature of automatic
sprinklers above and/or adjacent to the oven(s) in the paint shop. If ambient
temperatures or emergency conditions occur that requires a change in the
sprinkler temperature rating, the following should apply:
Change the rating of the sprinkler heads to “High” temperature

classification - 250 F to 300 F (121 C to 149 C)
and
Replace the sprinkler heads one bay or 30-ft. (9-m) (whichever is greater)
beyond the perimeter of the oven(s).
The use of high temperature heads is not limited to the ceiling sprinkler
system. Additional areas for consideration may include under walkways,
ducts, adjacent to heater boxes, etc
14 Appendix
Level
Automatic sprinkler protection should be provided throughout the paint dripping

area, into the oven as far as paint drippage may occur, and under ovens that are
installed above floor level. Sprinklers may be required in the oven exhaust
ductwork.
The sprinkler system in all new or renovated ovens should be manually

controlled. If ductwork protection is required, the system should be hydraulically
designed flowing 40 heads at 30 gpm (113 L/min) from each head.
8.3.2.10.4 Heated Flash Zones
Heated flash zones consist of convection, infrared or a combination of these two

methods of heating within an enclosure to achieve an accelerated evaporation of
liquid carrier following a spray application of coating material. Typically, they are
located after base coat paint application and prior to the application of clear coat.
The zones may be employed either in a “modular” or “in-line” spray booth
arrangement.
The sprinkler design for exhaust systems should be based on a maximum of 40

heads flowing 30 gpm (113 L/m) from each head. Sprinklers should be on an
open head basis under control of a readily accessible control valve.
For infrared zones, sprinkler operating temperatures should be at least 68ºF

(38ºC) greater than the surface temperature experienced at the sprinkler head.
Infrared zones, 15-feet (5 meters) length and less, do not require automatic
sprinklers; however, two sprinklers should be provided at the beginning and end
of the infrared zone to serve as a water curtain. The sprinkler heads should be
spaced a minimum of 4.5-ft. (1.5-m) and a maximum of 6-ft. (2-m)
Convection zones should use sprinklers with a rating 50ºF (10ºC) above
maximum expected air temperatures.
8.3.4.1.1 Machining – Protection for Machine Enclosures
Sprinkler protection for machine enclosures should be designed to deliver a

minimum of 30 gpm (113 Lpm) for the 20 hydraulically most remote sprinkler
heads. Control valves located at an accessible level are recommended for these
systems.
15 Appendix
Level
Alternately, gaseous extinguishing systems may be employed.
Insulation Material
Description: Considerations and requirements for the selection of insulation

materials.
Prevention of oil absorption should be a primary consideration in selecting

insulating materials for machine enclosures, as contaminated insulation is a
greater fire hazard.
Provide fiberglass insulation or mineral fiber insulation with plastic bag

encapsulation. This will help minimize absorption potential of exposed insulation
material and its inherent increase in fire hazard.
Polyurethane foam, polyisocyuranate foam, and other types of plastic insulation

may be used as follows:
For prefabricated wall and ceiling panels, panels listed in any of the
following categories are acceptable:
o Underwriters' Laboratories Building Materials Directory as "Insulated

Wall Constructions (NYVQ)" (large scale corner test)
o Underwriters' Laboratories Building Materials Directory as "Interior

Building Constructions (OEQX)" (small scale corner test)
o Factory Mutual Approval Guide as "Walls-Ceiling Construction-Class I

Fire Rated" (large scale corner test)
For other types of insulation used as components of construction, exposed

wall or ceiling insulation is not acceptable due to the "wicking effect" of the
insulation material.
Curtain materials may be used for enclosures subject to the following:
o Plastic curtains used for enclosure walls should be listed as flame

resistant when tested in accordance with NFPA 701.
16 Appendix
Level
o Plastic curtains used for enclosure entrance or exit openings less than
10 ft2 (0.93 m2) may be non-listed ordinary type materials.
8.3.6.2.1 Warehousing – Control of Hazards – Powered Industrial Trucks
Battery chargers should not be located in the racks or adjacent to combustible

storage. Arrangements that comply with the WFG opportunity charging
specification are acceptable.
8.3.6.3.3 Warehousing - Fixed Automatic Fire Suppression for Rack Storage
The following are commodity-specific protection recommendations for rack

storage:
Class I through Non-Exposed Group A Plastic (expanded and non-

expanded) - commodities up to a height of 25 ft. (7.6 m), protect in
accordance with NFPA 13, but to a density of no less than 0.3 gpm/ft2
(12.2 L/min/m2) over 4,000 ft2. (372 m2).
Exposed Group A Plastic - Rack storage heights up to 10 ft. (3.1 m)

require a minimum density of 0.30 gpm per ft2 (12.2 L/min/m2) over 4,000
ft2 (372 m2).
8.3.7 Offices
Automatic sprinkler systems should be provided in the following areas: drafting

rooms; laboratory and experimental areas; storage, printing and similar rooms
containing paper, cloth, other combustible materials or hazardous operations;
janitor's closets and kitchen areas.
17 Appendix
GENERAL MOTORS PAINT FIRE
GENERAL TECHNICAL REQUIREMENTS PROTECTION
GM BILL OF PROCESS
Document Number.Rev: 34950.D
Fire Protection Technical Requirements
Engineer(s): James Sute – GM Global Paint and Polymers Center

Bill Sheppard - GM Global Security
Wallie Williams – GM Global Security
Owner: Paint
Date: 15AU08
Manufacturing Partition Codes: 63.00.00
BOM Row Number(s):
APPLIES TO: ALL GM PAINT SHOPS
Sequence No.:
LID NO.: 5040, 5110, 8100, 8200, 8300
Table of Contents
Topic Page
1. SCOPE ...............................................................................................................................................3
2. GENERAL ..........................................................................................................................................3
2.1. BUILDING CONSTRUCTION .............................................................................................................3
2.2. CONTRACTOR REQUIREMENTS ......................................................................................................4
2.3 FIRE PROTECTION INSTALLATIONS AND EQUIPMENT ........................................................................4
3. SPECIFIC DESIGN DATA .................................................................................................................6
3.1. GENERAL .....................................................................................................................................6
3.2. BUILDING SPRINKLER PROTECTION ...............................................................................................6
3.3. PHOSPHATE AND ELPO MACHINES ................................................................................................7
3.4. PROCESS ENCLOSURES ...............................................................................................................7
3.5. SPRAY BOOTHS ............................................................................................................................7
3.6. ROTARY ATOMIZER (ESTA) SPRAY BOOTH ZONES – FLAMMABLE PAINTS ...........................................8
3.7. ROTARY ATOMIZER (ESTA) SPRAY BOOTH ZONES – NON-FLAMMABLE PAINTS AND PURGE MATERIALS ..... 8
3.8. ROBOTIC ELECTROSTATIC SPRAY BOOTH ZONES ..........................................................................8
3.9. ROBOTIC NON-ELECTROSTATIC AND ELECTROSTATIC USING NON-FLAMMABLE PAINT .....................9
3.10. HEATED FLASH ZONE ...................................................................................................................9
3.11. DOSING PUMPS AND COLOR CHANGERS .....................................................................................10
3.12. HOSE RETRACTOR CABINETS ......................................................................................................10
3.13. FLASH TUNNELS / OVEN EXITS ...................................................................................................10
3.14. OVENS ......................................................................................................................................10
3.15. SPRAY ROOM – REPROCESSING OPERATIONS ONLY ...................................................................11
3.16. PAINT HOSPITAL – SPOT REPROCESSING....................................................................................12
3.17. LIMITED FINISHING W ORKSTATION ..............................................................................................12
3.18. CANOPIES, ENCLOSURES AND TUNNELS......................................................................................13
1 of 38 © 2008 GENERAL MOTORS CORPORATION 34950D
All rights reserved
When printed, this copy is uncontrollable. GM users should verify latest revision at http://paint.gm.com/facility.
Users outside of GM should verify latest revision at http://www.gmsupplypower.com.

3.19. AIR SUPPLY HOUSES AND SUPPLY PLENUMS ..............................................................................14

3.20. BOOTH SCRUBBERS, EXHAUST PLENUMS AND CONCRETE TUNNELS ..............................................14
3.21. AIR SCRUBBER CORRIDORS -BELOW SPRAY BOOTH LEVEL ............................................................14
3.22. DUCTWORK................................................................................................................................15
3.23. EXHAUST STACKS .......................................................................................................................15
3.24. SLUDGE ROOM...........................................................................................................................16
3.25. POWDER PAINT SYSTEMS...........................................................................................................16
3.26. FAN ROOMS AND PENTHOUSE ....................................................................................................17
3.27. PAINT MIX ROOM .......................................................................................................................17
3.28. PAINT STORAGE ROOMS .............................................................................................................19
3.29. EXPLOSION VENTING ..................................................................................................................20
3.30. IN-PLANT OFFICES .....................................................................................................................20
3.31. MULTI LEVEL BODY STORAGE (ASRS / BSC) AREAS ...................................................................20
4. MATERIAL REQUIREMENT............................................................................................................21
4.1. GENERAL ...................................................................................................................................21
4.2. PIPEWORK AND FITTINGS ...........................................................................................................21
4.3. HANGERS ..................................................................................................................................22
4.4. SPRINKLER HEADS .....................................................................................................................23
4.5. INSPECTOR TEST VALVES ...........................................................................................................23
4.6. SYSTEM DRAINAGE ....................................................................................................................23
4.7. HOSE SYSTEMS .........................................................................................................................23
4.8. SPRINKLERS BELOW OBSTRUCTIONS ..........................................................................................23
5. APPENDIX A -REQUIREMENTS FOR APPROVAL .......................................................................24
5.1. SPRAY BOOTH ELECTRICAL CLASSIFICATION ...............................................................................25
5.2. CONNECTION OF PAINT LINES TO THE SPRAY BOOTH ....................................................................26
5.3. ROTARY ATOMIZER (ESTA) MACHINE CABINETS ..........................................................................26
5.4. DELUGE SYSTEM DISCHARGE TEST IN ELECTROSTATIC PAINTING (ESTA) ZONES ...........................27
5.5. FORK LIFT CLASSIFICATION FOR PAINT MIX AND STORAGE ROOM ...................................................27
5.6. PAINT MIX AND STORAGE ROOMS – TOTE AND MIX CONTAINER VENTING .....................................27
5.7. ROTARY ATOMIZER (ESTA) STATIONS.........................................................................................27
5.8. PAINT LINE FLUSHING .................................................................................................................27
5.9. TWIN TANK SYSTEMS FOR COLORED PRIMER COAT (WATERBORNE PRIMER) ..................................28
5.10. MIXING AND DISPENSING OF CLASS I AND II FLAMMABLE LIQUIDS .................................................28
5.11. MIXING AND DISPENSING OF CLASS III COMBUSTIBLE LIQUIDS .....................................................28
5.12. STORAGE ROOM OF FLAMMABLE AND COMBUSTIBLE LIQUIDS ........................................................29
5.13. EXPLOSION VENTING ..................................................................................................................30
6. APPENDIX B ....................................................................................................................................32
6.1 OVERHEAD MACHINE CO2 SYSTEM .............................................................................................32
6.2 CABINET CO2 SYSTEM ................................................................................................................32
6.4 DELUGE SYSTEM........................................................................................................................32
6.5 SPRINKLER SYSTEM ...................................................................................................................32
7. APPENDIX C – LOGIC DIAGRAMS ................................................................................................33
7.1. DIAGRAM 1..............................................................................................................................33
7.2. DIAGRAM 2..............................................................................................................................34
7.3. DIAGRAM 3..............................................................................................................................35
7.4. DIAGRAM 4..............................................................................................................................36
7.5. DIAGRAM 5..............................................................................................................................37
8. REVISION HISTORY .......................................................................................................................38

All rights reserved

Revision Status
Date: Change Control No.: Revision: Reason/Need:
15AU08 003-08 D 2008 Update
1. SCOPE
This document shall apply to all new and renovated GM paint shops.
This document is based on General Motors and Insurers requirements. Local legal
requirements that are more stringent shall be applied.
Exceptions to this document must be submitted to and approved by the responsible GM
operating group (GPPC, GME, LAAM, GMAP) and GM Global Security.
It is the responsibility of the contractor to follow all referenced standards, since this document
cannot be all-inclusive. Where not specifically outlined, if deviations may occur, the installation
shall be in accordance with the GM Fire Prevention and Protection Section of GM Global
Security Manual. Deviations to the Manual and this document shall be reviewed by GM Global
Security, in cooperation with appropriate Regional Security and Facilities Engineering
personnel.
Definitions:
Shall = indicates a mandatory requirement
Should = indicates a recommendation or that which is advised but not required
2. GENERAL
2.1. Building construction
Noncombustible construction is required for all buildings.
Insulation of roof and walls shall be with noncombustible materials in accordance with the
provisions of Chapter 3 of the General Motors Fire Prevention and Protection of the GM
Security Global Manual.
The following material should not be used or only after separate review and acceptance
2
1. Material with a bituminous content of more than 0,7 kg/m² (0.143 lb/ft ) shall not be used in
roof construction as a vapor barrier.
2. Foam material such as Polyurethane shall not be used as insulation material on roof and
wall constructions.
3. The wall or roof insulating material shall be generally in compliance with a Class A material
according DIN 4201. Only FM or UL listed panels shall be used.

All rights reserved

Foamed plastic filled wall construction, for interior panels, modular panels and exterior side wall
shall have pass a Factory Mutual Full Scale Corner Test and be FM approved (or equivalent)
for use in sprinkler-protected buildings (as specified in the GM Global Security Manual, Chapter
3). The ASTM E-84 Tunnel test is not considered a relative test.
Roofing system shall be rated by UL as a “fire classified“ assembly or FM class 1 (for interior
exposure) with a UL listed class A roof covering (for exterior exposure). Equivalent ratings by
other recognized testing laboratories may also be accepted.
Gravity type Heat & Smoke Vents are not required according to GM standards. However, local
codes and requirements of local authorities having jurisdiction shall be considered, clarified,
3
and variances received as necessary. In addition, smoke removal at the rate of 0,45 m /min
2
per square meter (1.5 cfm/ft ) of floor area shall be accomplished by mechanical ventilation.
(See Chapter 3 of the General Motors Fire Prevention and Protection Section of the GM
Security Manual.)
2.2. Contractor requirements
The contractor shall be well experienced in NFPA fire protection installations. In addition, the
contractor must demonstrate, as a minimum:
 adequate engineering capacity
 sufficient manpower for installation
 sufficient ability to service
 three years minimum experience in installing fire extinguishing systems
 Registration and approval as required by local authorities (in Europe registered by
local fire protection associations and ISO 9001 certified.)
To exhibit adequate experience and technical reliability the contractor should be prepared to
provide references upon request.
The contractor must guarantee adequate qualified manpower with appropriate experience in
installation of extinguishing systems, and that these employees will be in place during the fire
protection construction period. In addition, the job must have with a sufficient number of
supervisors for the job size who have adequate written and verbal skills.
All drawings and documents shall be submitted to XL GAPS for review and acceptance before
installation begins.
2.3 Fire protection installations and equipment
All equipment shall be listed and/or approved for its intended purpose by a recognized testing
laboratory such as Underwriters Laboratories (UL) or Factory Mutual (FM). Listed means
equipment, materials, or services included in a list published by an organization acceptable to
the authority having jurisdiction and concerned with evaluation of products or services that
maintains periodic inspection of production of listed equipment or materials or periodic
evaluation of services and whose listing states either that the equipment, material, or service
meets appropriate identified standards or has been tested and found suitable for a specified
purpose.
Sprinkler installation shall be based on the most recent edition of NFPA 13 - Standard for the
Installation of Sprinkler Systems.
Fire protection systems shall be protected to prevent piping damage in earthquake zones.
Earthquake zones shall be defined by a registered professional institution.

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Building sprinkler systems shall be in full operational service before combustible material and/or
equipment is moved into the building.
The integrity of the fire protection system remains the responsibility of the contractor until final
acceptance of the system has been obtained. Prior to final acceptance, systems may be placed
in temporary service to provide some level of fire protection. During this period, operation of the
fire protection system shall be coordinated with site Security. The guarantee for a fire protection
system begins when final acceptance without deficiencies has been obtained.
Automatic sprinkler protection shall be provided for the entire building, including inside
concealed spaces, below platforms and other obstructions.
Sprinklers are required below all obstructions (e.g. platforms, ducts, closed conveyer or piping,
stairs, underneath grillage (gratings) that exceed 1200 mm (48 inches) in width. For small
obstructions the sprinkler system shall be designed according pipe schedule OH or XH (see
paragraph 4.8). For large obstructions the sprinkler system shall match the ceiling sprinkler
design and be hydraulically calculated.
The maximum base of riser pressure demand shall not exceed 6,1 bars (90 psi). An exception
to exceed 6,1 bars (90 psi) is allowed on an individual riser basis when all of the following
conditions are met: 1) the maximum base of riser pressure demand shall be calculated back to
the water supply, 2) the calculated pressure at the water supply shall not exceed 90% of the
actual available water supply at that point, and 3) the actual available water supply shall be
based on the current water supply test.
Each sprinkler system shall have an individual lead-in from the fire loop with a separate post
indicator valve (PIV) in each line. The building installation starts with the floor flange unless
otherwise stated in the contract.
All sprinkler protection shall be automatic unless otherwise noted.
Provide portable fire extinguishers of the appropriate type and quantity per NFPA 10 throughout
the building.
Inside hose stations connected to the sprinkler system shall be installed so that two hose
streams will reach any point. For details refer to Material Requirements.
Roof hose stations or hydrants shall be provided and arranged to reach designated hazard
areas of the roofs. Roof hose stations or hydrants are not required on roofs where there are no
penthouses, heater houses, spray booth stacks, etc.. The distance between roof hydrants shall
not exceed 90 m (300 ft).
Roof hydrants or dry pipe risers to the roof areas where required by the authority having
jurisdiction shall be provided with hose couplings on both ends, preferably placed in the
proximity of a yard hydrant.
Fixed access ladders, stairs, bridges or ramps of steel or aluminum, shall be provided so that
any level or area of the roof may be reached unabated. For new construction, stairs shall be
installed for access from ground level to the roof.
All water flow alarms shall be transmitted as a supervised signal to the facility alarm system.
Hose allowance for inside hose stations is 380 L/min (100 gpm) at the area of application for all
systems per NFPA 13.

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Total hose allowance for hydrants and inside hose requires 1900 L/min (500 gpm) for 4-14
2 2
L/min/m (0.1 -0.35 gpm/ft ) and 2840 L/min (750 gpm) for all others added at the lead in
connection to the fire loop. A separate hydrant system shall not be used unless required by the
authority having jurisdiction.
Manual fire alarm stations shall be located inside and adjacent to emergency exits with a
maximum travel distance of 61 m (200 ft.).
The location of the extinguishers, manual fire alarm stations and inside hose reels shall be
reviewed and accepted by plant security.
Spray booth deluge and closed head sprinklers shall each be supplied independently of plant
ceiling sprinklers. The supply should encompass a two-way feed arrangement from the yard
main with the risers and sectional control valves arranged to minimize impairment potential.
A separate water flow alarm shall be installed for each spray booth and connected to the facility
alarm console. The spray booth ends at the exit of the scrubber section.
If field joining of the paint circulation piping outside the paint mix room relies on nonmetal
gaskets to prevent leakage, all primer surfacer, topcoat and solvent pumps shall be interlocked
with the building fire protection system to shut down in the event of a sprinkler discharge in the
vicinity of the paint circulation lines.
Emergency manual paint and thinner pump shut down stations shall be installed outside spray
booths and arranged so that the unobstructed travel distance to each stop switch is not over 23
m (75 ft.) from each booth exit. This shut down station shall be interlocked to provide an alarm
on the plant proprietary console. (See Process Fire Protection Systems Logic Diagrams in
Appendix C for additional shut down function requirements).
Identification of Valves and Piping

All control, drain, and test connection valves shall be provided with permanently marked metal
or rigid plastic identification signs denoting the normal position and coverage area of the valve.
The signs shall be secured with corrosion resistant wire, chain, or other approved means.
The sprinkler piping shall be identified with legends consisting of white letters set against a red
background of appropriate size to provide the maximum contrast and legibility. Preprinted pipe
marking systems may be used, provided they are of durable materials, are securely attached,
and meet the size and color requirements of this standard and applicable local requirements.
3. SPECIFIC DESIGN DATA

3.1. General
Silicone containing materials and equipment shall not be permitted to be used in the paint shop
including all fire protection systems. This includes sealers, caulking, lubricants, and oils.
The maximum and minimum distance between sprinkler heads / branch lines shall be 3,66m
(12 ft) and 2,44m (8 ft) respectively. Sprinkler spacing and area of application in this document
are the maximum allowed.
3.2. Building Sprinkler Protection

2 2
Water density 12 L/min/m 0.30 gpm/ft
2
Sprinkler spacing 9 m² 130 ft
2
Area of application 280 m² 3,000 ft
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2
Area of protection 4831 m² / alarm valve 52,000 ft / alarm valve
Temperature rating Ordinary (57-77 °C ) Ordinary (135-170°F)
Temperature rating High (121-149 °C ) High (250-300 °F)
above and around ovens
Due to Emergency cool-down procedure used for the ovens and possible building ventilation
failures the sprinklers above and around ovens shall be High Temperature Classification. This
zone should extend one bay or 9 m (30 ft.) whichever is greater. This should include under
walkways, ducts and adjacent to heater boxes.
3.3. Phosphate and Elpo Machines
Sprinkler protection is not required inside the phosphate and Elpo machines. This includes the
tunnels between phosphate and Elpo, between stages and up to the Elpo oven.
Sprinklers are required below these machines if the height is enough to allow combustible
storage.
3.4. Process Enclosures

Definition: This section includes enclosures for the following operations: Sanding and Prep,
Finesse, Blow-off, Feather Dusters, and Solvent wipe.
a) Sprinkler protection:
2 2
2 2
Sprinkler spacing 9m 100 ft
Temperature rating Ordinary (57-77 °C ) Ordinary (135-170 °F )
2 2
Area of application Entire enclosure (max. 280 m ) Entire enclosure (max 3,000 ft )
b) Water supply for enclosure sprinklers

 Automatic sprinkler piping for each enclosure shall be controlled by readily accessible
listed valves.
 Exhaust systems do not require sprinkler protection.
 Enclosure sprinklers shall be supplied from plant ceiling (building) sprinklers.
3.5. Spray booths

General: Aluminum is an unacceptable basic construction material for paint spray booths. Booth
windows shall be wired or laminated safety glass as a minimum.
2 2
2 2
Sprinkler spacing 8,4 m 90 ft
Temperature rating Ordinary (57-77 °C ) Ordinary (135-170 °F )
2 2
Area of application Entire booth (max. 280 m ) Entire booth (max.4,000 ft )
b) Water supply for spray booth sprinklers

 Automatic sprinkler piping for each spray booth including its exhaust system shall be
controlled by readily accessible listed valves.
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 Booth sprinklers shall be supplied independently of plant ceiling (building) sprinklers.

 The supply shall consist of a two-way feed arrangement from the yard main and
sectional control valves to minimize impairment potential.
 A separate water flow alarm shall be installed for each spray booth system.
b) Refer to Process Fire Protection Logic Diagrams in Appendix C for additional requirements.
3.6. Rotary Atomizer (Esta) Spray Booth Zones – Flammable Paints

This section applies to Solvent borne and Water borne Paints determined to be self-sustaining
burning using the triangle diagram from the PTB Institution W-57 Test. NOTE: This section
shall also apply to paints and solvents that have not been tested.
General: In addition to the general requirements for spray booths, the following additional
protection is required. Note: For further discussions of the additional fire protection required,
refer to Appendix B, Section 6.
a) Booth sprinkler protection shall to be extended to cover the inside of the side machines and
support cabinets of the roof machines if located outside of the spray booth enclosure.
b) Special CO2 and Deluge protection are required as described below:
 A two shot liquid CO2 system shall be provided to protect the side cabinets (including
those for the roof machine). The roof machine shall be protected by a two shot liquid or
gaseous CO2 system. A 34% concentration of CO2 shall be achieved within one minute
after agent release. Once a concentration of 34% is achieved, it must be held for one
additional minute.
 A deluge system shall be provided as the final protection for the affected zone. IR
detectors shall be installed to provide overlapping coverage of the entire spray zone
with or without a vehicle present and regardless of the position of the automation.
 Any one IR detector in the zone will activate spray shutdown in the zone. If after a 10
second delay there are two detectors in alarm the deluge shall activate.
 Means for manual electrically operated release of systems are to be available on both
sides of the booth. Mechanical means for release are to be available at the deluge
valve and the CO2 storage tanks.
 Interlocking and all other features are required as per “Logic Diagram 3” in Appendix C.
c) Water deluge system

2 2
2 2
Area of application Entire zone Entire zone
3.7. Rotary Atomizer (Esta) Spray Booth Zones – Non-flammable Paints and Purge Materials
This section applies to Waterborne Paints and Purge Materials determined to be non-burning or
non-self-sustaining burning using the triangle diagram from the PTB Institution W-57 Test.
In addition to the general requirements for spray booths, booth sprinkler protection shall be
extended to cover the inside of the side machines and support cabinets of the roof machines if
located outside of the spray booth enclosure.
 Special CO2 and Deluge protection are not required.
3.8. Robotic Electrostatic Spray Booth Zones
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This section applies to Solvent borne, Waterborne Paints and Purge Materials determined to be
self-sustaining burning using the triangle diagram from the PTB Institution W-57 Test. NOTE:
This section shall also apply to paints and solvents that have not been tested.
General: In addition to the general requirements for spray booths, the following additional
protection is required. Note: For further discussions of the additional fire protection required,
refer to Appendix B, Section 6.
a) Booth sprinkler protection shall be extended to cover the inside of robot rail enclosures or
covers. 7,5m (25 ft) is the maximum length of rail where a single head located in the center
can be used. Longer lengths will use standard spacing design
b) Special CO2 and Deluge protection are required as described below:
 A liquid CO2 system is not required in the cat-trac (robot servo motor and electrostatic
power) if the power cables are listed.
 A deluge system shall be provided as the final protection for the affected zone. IR
detectors shall be installed to provide overlapping coverage of the entire spray zone with
or without a vehicle present and regardless of the position of the automation.
 Any one IR detector in the zone will activate spray shutdown in the zone. If after a 10
second delay there are two detectors in alarm the deluge shall activate.
 Means for manual electrically operated release of systems are to be available on both
sides of the booth. Mechanical means for release are to be available at the deluge valve
c) Water deluge system for the rotary atomizer zones
2 2
2 2
2 2
Area of application Entire zone (max. 372 m ) Entire zone (max.4,000 ft )
3.9. Robotic Non-electrostatic and Electrostatic Using Non-flammable Paint

This section applies to Waterborne Paints and Purge Materials determined to be non-burning or
non-self-sustaining burning using the triangle diagram from the PTB Institution W-57 Test.
a) The spray booths closed head sprinkler protection is adequate for robotic zones using non-
flammable paint. Special CO2 and Deluge protection are not required. Listed paint equipment
shall be installed.
b) Booth sprinkler protection shall be extended to cover the inside of robot rail and cat-trac
enclosures. 7,5m (25 ft) is the maximum length of rail where a single head located in the center
can be used. Longer lengths will use standard spacing design
c) Interlocking and all other features are required as per “Logic Diagram 3” in Appendix C.
3.10. Heated Flash Zone

The heated flash is an ordinary electrical hazard except as required by the 915 mm (3-foot) rule
(according to NFPA) for spray booths.

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Sprinkler protection
2 2
2 2
Temperature rating
Calming/Cooling Zones Ordinary (57-77 ºC) Ordinary (135-170 °F)
Inside Heat Zones 28 °C above maximum start- 50 F above maximum start-
up or operating temperature up or operating temperature
Sprinkler protection shall be provided within the exhaust duct up to and just beyond the first
filter bank.
3.11. Dosing Pumps and Color Changers

If dosing pumps and color changer equipment is installed in an enclosure, sprinklers shall be
provided, supplied by the booth system.
3.12. Hose retractor cabinets

Paint hose retractor cabinets along the manual spray paint booth shall be arranged as follows:
 Cabinets shall be enclosed by metal panel structure at the spray booth level and
booth tank level.
 A DN25 to DN50 (1 to 2 inch) drain shall be provided at the bottom of enclosure (at
tank level)
 Sprinkler protection shall be installed inside of the enclosure
3.13. Flash Tunnels / Oven Exits
Sprinkler protection shall be provided up to the entrance of the oven. For elevated ovens, the
oven entrance shall be considered the beginning of the heated ceiling area. This protection
shall be an extension of the spray booth system. Immediately adjacent to the entrance and exit
(9 m (30 ft.)) shall be protected with High Temperature classification heads to accommodate
possible oven balance conditions.
2 2
2 2
Temperature rating Ordinary (57-77 C) Ordinary (135-170 F)
Temperature rating at High (121-149 C) High (250 – 300 F)
entrance and exit
2 2
Area of application Entire zone (max. 372 m ) Entire zone (max.4,000 ft )
3.14. Ovens
Sprinkler protection inside ovens is not required for metal bodies or components. Ovens drying
combustible panels or parts including final repair ovens must be protected in accordance with
the table below.

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2 2
2 2
Temperature rating 28 C above maximum start- 50 F above maximum start-
inside Oven up or operating temperature up or operating temperature
2 2
Area of protection 3715 m / alarm valve 40,000 ft / alarm valve
2) 2
Area of Application Entire zone (max 280 m Entire zone (max 3,000 ft )
Sprinkler protection shall be a closed head dry system on a manual control basis.
3.15. Spray Room – Reprocessing Operations Only

Definition: A spray room is a power ventilated, enclosed off-line area for multiple vehicles where
paint is applied to small defects or entire panels.
2 2
2 2
o
Temperature rating Ordinary (57-77 C ) Ordinary (135-170 F)
2 2
Area of application Entire (max. 280 m ) Entire (max.3,000 ft )
b) Electrical equipment in spray rooms shall conform to NFPA 33 and NFPA 70 for Class 1,
Division 1 (Zone 1) Locations.
c) The curing and polishing enclosures shall be electrically classified as ordinary hazard except
as required by the 3-foot rule (according to NFPA 33) separated from Class 1, Division 1
(Zone 1) Locations.
d) Spray apparatus shall be interlocked to prove ventilation.
e) Spraying equipment shall be interlocked with the heating apparatus to not allow spraying
during drying.
f) Spray rooms shall be separated by non combustible walls and ceiling.
g) Any attached enclosure for baking and polishing shall be per paragraph 3.4 - Process
Enclosures. If it is an attached oven refer to Paragraph 3.14
h) The ventilation shall provide a minimum of 6 air changes per hour.

i.) Ductwork
The exhaust ductwork from the collector modules to and just beyond the final filter shall be
provided with wet sprinklers installed not more than 3,7 m (12 feet) apart in horizontal or
vertical runs. Sprinkler heads installed inside ductwork must be removable to allow for
changing as needed. The supply ductwork from the air supply house to the plenum does not
require sprinklers.
Fire protection for the air supply house and booth plenum will not be required when UL900
Class 1 or Class 2 filters are installed.
Pipe sizing may be according to pipe-schedule XH or hydraulically design based on 20
heads operating at 2 bar.

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Readily accessible control valves to be installed in the supply line, to be secured by

chain and lock or equipped with valve supervision.
3.16. Paint Hospital – Spot Reprocessing
Definition: A Paint Hospital is a power ventilated enclosed off-line area for multiple vehicles
where less than 4,5 ml (0.152 fl. oz) of paint is applied per job to defects of nominal 3 cm (1.2
in) diameter or less.
2 2
2 2
o
2 2
Area of application Entire (max. 280 m ) Entire (max. 3,000 ft )
b) Electrical equipment in paint hospitals shall be unclassified.
c) Spray apparatus shall be interlocked to prove ventilation. The bake lamps do not need to be
interlocked with the ventilation.
d) The ventilation shall provide a minimum of 6 air changes per hour.
e) Paint Hospitals shall be separated by non-combustible construction from the surrounding

areas of the plant.
3.17. Limited Finishing Workstation

A limited finishing workstation is a facility for the repair of a vehicle where the amount of
material sprayed shall not exceed 3,8 ltr (1 gal) in any eight-hour period. The limited finishing
workstation shall be designed and constructed to have:
 a dedicated make-up air supply and air supply plenum;
 curtains or partitions that are noncombustible or limited combustible,
 a dedicated mechanical exhaust and filtration system; and
 an approved automatic extinguishing system
The curtains or partitions shall be fully closed during any spray application operations.
The area inside the curtains or partitions shall be considered a Class I, Division 1 (Zone 1) or
Class II, Division 1 (Zone 1) hazardous (classified) location, as defined by NFPA 70. A Class I,
Division 2 (Zone 2) or Class II, Division 2 (Zone 2) hazardous (classified) location shall extend
horizontally and vertically beyond the volume enclosed by the outside surface of the curtains or
partitions as follows:
If spray application equipment is interlocked with the exhaust ventilation system, a 1,5 meter (5
ft.) Class 1 Division 2 (Zone 2) area extends from the curtain (see Figure 1).

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FIGURE 1
If spray application equipment is not interlocked with the exhaust ventilation equipment, a 3,0
meter (10 ft.) Class 1 Division 2 (Zone 2) area shall extend from the curtain.
Sprinklers are required in the filter box and under the overhead filters.
Sprinkler protection:
2 2
2 2
o
Temperature rating Ordinary (57-77 C) Ordinary (135-170 F)
Area of application Entire station Entire station
3.18. Canopies, Enclosures and Tunnels
 In order to not require sprinkler protection below plastic canopies the polyethylene film used
for the ceiling of the canopy shall have a maximum thickness of 0,18 mm (7.0 mils) and be
adequately supported by a metal support frame or cables. The spacing for the metal
support for the plastic film shall not exceed 4,5 m (15 ft.).
 Tacky mesh canopy shall be woven polyethylene coated with a high tack, residue-free,
VOC-free adhesive with a fire retardant additive and supported by a metal cable or frame.
Fire breaks are not required for tacky mesh due to its slow burning properties.
 If required, provide sprinklers according to Diagram 5 in appendix C
 Combustibles shall not be stored below a canopy or inside an enclosure constructed of

plastic film / tacky mesh.
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 Manual operations may be performed below a canopy constructed of plastic film / tacky
mesh as long as egress for fire and safety is provided as required by code.
 The plastic / tacky mesh enclosure or canopy may span multiple conveyor lines when the
vehicle is completely non-combustible. The plastic /tacky mesh enclosure or canopy is
limited to one conveyor line in width when the vehicle has combustible panels.
 Flash tunnels between the spray booth and oven shall not be constructed of plastic film or
tacky mesh.
 Exposure of plastic / tack mesh canopies or enclosures to operations or vehicle bodies at

elevated temperatures such as the exit of bake ovens shall be avoided.
 Egress for fire and safety shall be provided as required by Life Safety Guidelines when
manual operations are performed.
See Diagram 5 in Appendix C for further clarification.

3.19. Air Supply Houses and Supply Plenums
The interior of air supply houses and supply plenums require sprinkler protection when
combustible filters are utilized. Sprinklers shall comply with the requirements of paragraph 3.5.
See paragraph 3.23 – Ductwork – for discussion of recirculated air systems.
Filters that are UL900 class 1 or 2 (DIN 4102 class B1 or equivalent) filters are considered non-
combustible.
3.20. Booth scrubbers, Exhaust plenums and Concrete tunnels
2 2
2 2
Area of application 40 heads in remote area 40 heads in remote area
2 2
o
Interior of exhaust tunnels up to the main stack shall be protected with sprinklers.
Sprinkler heads subject to paint over spray or similar shall be protected from spray residue by
lightweight paper or by polyethylene bags having a thickness of 0,075 mm that will (3 mils) or
less.
Sprinkler pipes and hanger assemblies including the hanger rods shall be made of stainless
steel grade 304 or owner approved alternate within booth scrubbers, exhaust plenums,
concrete tunnels and exhaust ducts up to the inlet of the exhaust fan.
Electrical equipment in the interior of booth scrubbers, exhaust plenums and concrete tunnels
shall conform to NFPA 33 and NFPA 70 for Class 1, Division 1, Group D (Zone 1) Locations
3.21. Air scrubber corridors -below spray booth level

When hose retractor cabinets are used, ventilation on a basis of 6 air changes per hour
independent of the size of the corridors is required and CH (hydrocarbon) detection system with
alarms connected to the plant proprietary alarm shall be provided.

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CH-detection to be provided shall be interlocked as follows:

20 % LEL - ventilation starts or continues to operate and local visual alarm
40% LEL – Audio alarm, signal to plant proprietary system and shutdown paint pumps
Building sprinkler protection shall be provided.
3.22. Ductwork
a) Spray Booths and Spray Rooms
Aluminum shall not be used for ventilation ductwork or ductwork structural support when
associated with a spray booth or spray room.
The exhaust ductwork from the spray booths and spray rooms must be provided with wet
sprinklers installed not more than 3,7 m (12 feet) apart in horizontal or vertical runs. The
means to remove and replace each individual sprinkler head shall be incorporated into the
design of the ductwork.
Ductwork from the air supply house to the booth plenum does not require sprinklers except
where exhaust air is recirculated to booth supply.
Electrical equipment in spray booth exhaust ducts shall conform to NFPA 33 and NFPA 70
for Class 1, Division 1, Group D Locations.
b) Recirculated Air Systems

For spray booth systems with recirculated air, sprinkler protection shall be provided within
this duct, any filter house, and the air supply house. Ductwork after the filter house or air
supply house does not require sprinklers. However, the supply plenum will require sprinklers.
Note: If the recirculated air does not travel through the air supply house, sprinklers are not
required in the air supply house as long as requirements of paragraph 3.17 are met.
Sprinklers shall comply with the requirements of paragraph 3.5.
In addition a CH (hydrocarbon) detector shall be installed in the recirculated duct after the
filter house. A warning signal shall be sent at a 20% CH level. At a 25% CH level an alarm
signal shall be sent to the facility alarm system and the fire interlock is energized. The fire
interlock shall deactivate booth air recirculation and direct the exhaust air to atmosphere.
The sludge removal water, air supply, bearing air and exhaust shall remain on at all times.
The hydrocarbon detector should be calibrated with methane or propylene. Propane should
not be used because it is too sensitive.
Electrical equipment in the recirculated air ducts, filter house and booth plenum shall
conform to NFPA 33 and NFPA 70 for Class 1, Division 1, Group D (Zone 1) Locations.
c) Process Enclosures
Ductwork for process enclosures does not require sprinklers. (See paragraph 3.4 for
definition of a process enclosure.)
3.23. Exhaust stacks
a) Exhaust stacks from process enclosures and ovens do not require sprinklers.

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b) Spray booth stacks, made of steel:

 Inside air ducts greater than 300 mm (12”) diameter require sprinkler protection up to
1 m (3 ft) below the roof. From 1 m (3 ft) below the roof to the top of the stack
provide manually controlled open sprinklers with the valve installed at the ground
level and permanently identified.
 Maximum spacing of sprinklers in the ducts to be 3,7 m (12 ft).
 Each sprinkler shall discharge 114 L/min (30 gpm) per head with 40 heads operating.
 Stacks over 1,8 m (6 ft.) in diameter or width shall have sprinklers installed on an
individually engineered basis with approval by the authority having jurisdiction.
c) Sprinkler protection for stacks made of concrete is not required.
d) Electrical equipment in spray booth exhaust stacks shall conform to NFPA 33 and NFPA 70
for Class 1, Division 1, Group D (Zone 1) Locations.
3.24. Sludge Room

Note: The sludge room is classified as an ordinary electrical hazard area.
Sprinkler protection shall be part of the building system (see paragraph 3.2).
3.25. Powder Paint Systems

General: The current designs for powder spray booths present a unique concern due to the
considerable time required to resume production after a sprinkler discharge. Any water
discharged into the booth will require cleaning in the area of the discharge and replacement of
any wet filter cartridges below the grating. In order to minimize potential lost production, the fire
protection system described in this document has been found acceptable by GM Corporate
Security, XL GAPS and GM GPPC.
a) Booth Protection
The powder spray booth, robot rail enclosures, and equipment closets shall be protected by
a pre-action sprinkler system providing a two (2) level fire protection system (see Logic
Diagram 4).
Level 1: When two FM approved flame detectors react to the presence of a flame:
a) Interlocks shall shut down all automatic powder equipment, conveyor, air
supply unit, exhaust fans, paint supply, high voltage, reclaim system, and
control air.
b) The pre-action sprinkler valve serving the booth shall be activated, which will
load water into the sprinkler piping.
Level 2: Sprinklers opened by heat from a fire will discharge water into the booth.
2 2
Sprinkler design density shall be 14 L/min/m (0.35 gpm/ft ) for the entire booth area
affected.
Sprinkler system shall be tested with air pressure to detect and correct any leakage prior to
testing the water fill.

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b) Ductwork
The exhaust ductwork from the collector modules to and just beyond the final filter shall be
provided with wet sprinklers installed not more than 3,7 m (12 feet) apart in horizontal or
vertical runs. The means to remove and replace each individual sprinkler head shall be
incorporated into the design of the ductwork.
The supply ductwork from the air supply house to the plenum does not require sprinklers
Fire protection for the air supply house and booth plenum will not be required when Class 1
or 2 filters are installed.
c) Storage / Distribution Room
The powder storage room shall be protected by an automatic wet sprinkler system. The
sprinkler system shall be designed and located to provide an effective distribution of water
throughout the entire room.
2 2
Sprinkler design shall be 12 L/min/m (0.30 gpm/ ft ) for entire area affected.
This room shall be considered an unclassified / normal electrical hazard. Proper house
keeping shall be maintained.
d) Bell Cabinets
The bell station side cabinets shall have automatic wet sprinkler protection as an extension
of the booth sprinkler system. CO2 protection is not required.
3.26. Fan Rooms and Penthouse

Note: The fan rooms and the penthouse shall be classified as ordinary electrical hazard areas.
Sprinkler protection shall be part of the building system (see paragraph 3.2).
Dry-pipe systems shall be installed where piping is subject to freezing.
3.27. Paint Mix Room

a) Sprinkler protection. All paint mix rooms shall be protected by building sprinklers.
2 2
2 2
2 2
Area of application 280 m 3,000 ft
2 2
Temperature rating Ordinary (57 - 77 C) Ordinary (135 - 170 F)
2 2
Density under mezzanine 24 L/min/m 0.60 gpm/ft
Unless otherwise required by local code, the building sprinklers shall be the only fire
suppression system installed in the paint mix room. Containment for discharge of sprinklers
shall be provided with capacity to hold 20 minutes of sprinkler discharge for the mix room
2 2 2 2
area up to a maximum of 280 m (3,000 ft ). 20 mins * 24 L/min/m * 280 m ( 20 mins *
2 2
0.60 gpm/ft * 3,000 ft ).
The sprinkler discharge containment tank shall be designed to comply with WFG
specifications and satisfy applicable local codes and regulations.
All rights reserved

In addition, when building sprinklers are the primary means of fire protection:
 Water flow shall shutdown all paint and solvent pumps.
 The room ventilation equipment should stay operating in the event of a discharge.
 Isolation dampers on supply and exhaust duct are not required.
b) Carbon Dioxide Fire Suppression
For installations in which a carbon dioxide fire suppression system is required due to local
codes or regulations, an automatic two-shot carbon dioxide system shall be provided in
addition to the closed head sprinkler system. For interconnected rooms, the quantity of
carbon dioxide shall be based on two shots for the volume of the larger room. The carbon
dioxide system shall be designed to operate before the sprinklers. CO2 protection shall
provide a 34 % concentration in one minute and hold at that level for 3 minutes. Time delays
and audible warning devices shall also be pneumatically operated. Containment for the
building sprinklers is not required when carbon dioxide fire suppression is utilized.
Design according to: NFPA No. 12

To be actuated by: Actuation system proposed: shall be fixed
temperature rate compensated heat
detectors in single line arrangement
Temperature rating: Ordinary but less than sprinkler
temperature rating
Interlocks in conjunction with the detection system of the CO2 system shall be arranged
as follows:
 Shut off all paint material supply lines, air supply and exhaust fans, pumps, agitators,
barrel roller, compressed air supply, etc.
 Close fire doors and dampers.
c) Electrical equipment in paint mix rooms shall conform with NFPA 70 National Electric Code
for Class I, Division 1, Group D (Zone 1) locations. All equipment shall be visibly grounded.
Racks for paint materials shall be grounded. Grounding methods used shall be in
accordance with NFPA 77 - Static Electricity.
d) For explosion relief venting see paragraph 3.29
e) Miscellaneous Requirements
 Mix tanks for both solvent based and water based paint shall be provided with adequate
combination flash arrestors that are vented to the room interior. Exception: Paints
containing isocyanate materials shall be vented to a safe location at the building
exterior. This vent shall have a combination conservation–flame arrestor discharge cap.
 The combination storage and mix room shall be separated from other building areas by
a three hour rated firewall. Openings are to be protected by approved fire rated
(commensurate with the wall) fire dampers and fire doors.
 Floors shall be concrete. If drains are installed, they shall gravity feed to a containment
tank sufficient to contain spillage from the largest container in the room.
 Floors shall be liquid tight and have 100 mm (4 “) high curbs or ramps at door openings
to outside and 100 mm (4 “) to paint shop.
 Room shall have at least two exits for emergency egress.
All rights reserved

 Continuous fresh air mechanical ventilation system shall be provided on a basis of 6 air
changes per hour: The 6 air changes per hour are calculated only for the lower 3
meters (10 ft) of the room.
- 80% of the volume should be exhausted at floor level, 150 mm (6“) above floor
- 20% of the volume should be exhausted near the ceiling level
- Supply air will be delivered according to good engineering practice to prevent any
dead areas in the room.
 Air supply systems may be direct fired natural gas if the air supply house is mounted
outside the paint mix room and UL listed Class 1 or 2 (DIN 4102 Class B1 or
equivalent) filters are used.
 The supply air system shall be capable of supplying air at 50% RH at the winter design
conditions.
 Ventilation failure alarm shall be provided. This should be a local alarm and signal to
plant proprietary system upon the loss of either supply or exhaust airflow. A ventilation
failure does not need to shutdown the paint mix pumps or agitators.
 Exhaust fans shall be non-sparking type.
 An emergency shut off button to stop the paint mix equipment shall be installed outside
the room.
 CH-detection to be provided if required by local authorities and shall be interlocked as
follows:
20 % LEL - - Ventilation starts or continues to operate and local visual alarm
40% LEL - - Audio alarm, signal to plant proprietary system and shutdown paint and
solvent pumps.
3.28. Paint storage rooms

Note: If paint is dispensed or paint containers are opened in this area, the provisions of the
“Paint Mix Room” shall apply.
a) Sprinkler protection
2 2
2 2
Sprinkler spacing 9m 100 ft
2 2
2 2
Temperature rating Ordinary (57 -77 C) Ordinary (135-170 F)
In-rack sprinklers are required for storage of drums in racks.
b) For explosion relief venting see paragraph 3.29

c) Miscellaneous Requirements
 Electrical equipment in storage rooms shall conform with NFPA 70 National Electric
Code for Class I, Division 2, Group D (Zone 2) locations.
 Racks used in storing paint materials shall be grounded. Grounding methods used shall
be in accordance with NFPA 77 - Static Electricity.

All rights reserved

 The combination storage and mix room shall be separated from other building areas by
a three hour rated firewall. Openings are to be protected by approved fire dampers and
doors. If the paint mix and storage rooms are designed as separate hazards, the
dividing wall shall have a minimum rating of two hours. These walls shall conform to
the provisions of General Motors Fire Prevention and Protection Manual, Section 3.
 The integrity of fire walls or fire barrier partitions must be maintained by airtight filling of
any abandoned or partially used openings to the full wall thickness with materials
having the same fire resistance rating as the wall.
 Floors shall be concrete. If drains are installed, they shall gravity feed to a containment
tank sufficient to contain spillage from the largest container in the room.
 Floors shall be liquid tight and have 100 mm (4 “) high curbs or ramps at door openings
to outside and 100 mm (4 “) to paint shop.
 Room shall have at least two exits for emergency egress.
 Continuous fresh air mechanical ventilation system shall be provided on a basis of 6 air
changes per hour. The 6 air changes per hour are calculated only for the lower 3
meters (10 ft) of the room.
- 80 % of the volume should be exhausted at floor level, 150 mm (6“) above floor.
- 20 % of the volume should be exhausted near the ceiling level.
- Supply air will be delivered according to good engineering practice to prevent any
dead areas in the room.
 Air supply systems may be direct fired natural gas if the air supply house is mounted
outside the paint mix room and UL listed Class 1 or 2 (DIN 4102 Class B1 or
equivalent) filters are used.
 The supply air system shall be capable of supplying air at 50% RH at the winter design
conditions.
 Ventilation failure alarm shall be provided. This should be a local alarm and signal to
plant proprietary system upon the loss of either supply or exhaust airflow. A ventilation
failure does not need to shutdown the paint mix pumps or agitators.
 Exhaust fans shall be non-sparking type
3.29. Explosion Venting
Explosion relief venting shall be provided in accordance with the provisions of General Motors
Fire Prevention & Protection Section of the Global Security Manual. If there is no dispensing in
the storage room explosion venting is not required.
3.30. In-Plant Offices

2 2
2 2
Sprinkler spacing 12 m 130 ft
2 2
Temperature rating Ordinary (57-77 C) Ordinary (135-170 F)
2 2
Sprinkler protection is not required for noncombustible offices less than 9 m (100 ft ).
3.31. Multi level Body Storage (ASRS / BSC) Areas

No additional rack sprinklers are required in these multi story body storage systems if the
vehicles are non-combustible and the skids are not the same skids used in the painting
process. Ceiling sprinkler coverage is deemed sufficient.
All rights reserved

4. MATERIAL REQUIREMENT
4.1. General
All equipment shall be listed and/or approved for its intended purpose by a recognized testing
laboratory such as Underwriters Laboratories (UL) or Factory Mutual (FM). Listed means
equipment, materials, or services included in a list published by an organization acceptable to
the authority having jurisdiction and concerned with evaluation of products or services that
maintains periodic inspection of production of listed equipment or materials or periodic
evaluation of services and whose listing states either that the equipment, material, or service
meets appropriate identified standards or has been tested and found suitable for a specified
purpose.
Sprinkler design shall be based on the most recent edition of NFPA 13 – Standard for the
Installation of Sprinkler Systems.
4.2. Pipework and Fittings
Sections of pipes greater than DN 65 (2 ½”) shall be joined by means of welded flanges or via
grooved pipe system. (ie. Victaulic, Gruvlok...) Piping equal to or less than DN 65 (2 ½”) shall
have threaded joints.
4.2.1 All pipe and fitting materials shall be based on NFPA 13 requirements. Schedule 10
light wall piping is permitted in those instances where the water supply is considered
potable.
4.2.2 For European Installations, welding inside buildings is strictly forbidden. All piping shall
be prefabricated outside the building.
4.2.3 For European installations, the pipe and fitting materials listed in the table below shall
be used.
Pipes Bends
welded steel pipe accorded to DIN 2458 / seamless steel bends accorded to DIN 2605
EN 10220 St 37 accord. To DIN 1626 for standard 3S, material St33 , according to DIN /
welding EN 10025
323,9 mm x 5,6 mm standard wall 323,9 mm x 7,1 mm wall thickness
thickness
273,5 mm x 5,0 mm " 273,1 mm x 6,3 mm "
219,1 mm x 4,5 mm " 219,1 mm x 5,9 mm "

168,3 mm x 4,0 mm " 168,3 mm x 4,5 mm "
139,7 mm x 3,6 mm " 139,7 mm x 4,0 mm "
114,3 mm x 3,2 mm " 114,3 mm x 3,6 mm "
88,9 mm x 2,9 mm " 88,9 mm x 3,2 mm "
76,1 mm x 2,6 mm 76,1 mm x 2,9 mm

All rights reserved

Threaded-Pipes Fittings
steel pipes accorded to DIN 2440 material For  DN 65: threaded malleable fittings
St 33 accord. DIN / EN 10025 for screw accorded to DIN 2950 / EN 10242.Connections
connection to large diameters by means of threadolet
76,1 mm x 3,65 mm (2 1/2") Tees: no prefabs. Forged fittings but directly
welded connections for equal and different
60,3 mm x 3,65 mm (2)
diameters, accorded NFPA No. 3.12.2.
48,3 mm x 3,25 mm (1 1/2")
Reducer: accord. DIN 2616
42,4 mm x 3,25 mm (1 1/4")
Flanges: accord. DIN 2633 (PN 16, welding
33,7 mm x 3,25 mm (1) neck).
26,9 mm x 2,65 mm (3/4“) Grooved-style joints are also acceptable. Max.
21,3 mm x 2,65 mm (1/2“) length of pipework between flanges : 7m (23 ft)
No jointing compound except steam-sealing quality shall be permitted and all joints shall be
wiped clean externally upon completion. For sprinkler head thread TPF packing shall be used.
4.3. Hangers
Hanger design shall be in accordance with NFPA No. 13 with the following exceptions:
- Pipes up to DN 40 (1 ½ in) diameter can be supported on the metal panel ceiling using
trapeze hangers.
- Pipes with DN 50 (2 in) diameter – support on metal panel ceiling with trapeze hangers
and every third hanger shall be supported on steel structure.
- The distance between hangers on pipes of  DN 80 can be up to 6 m (20 ft) if double
hangers on beams are utilized (VdS rule)
The hangers shall be designed to support five times the weight of the water-filled pipe plus 125
kg (275 Ibs) at each point of piping support.
Hangers certified by a registered professional engineer in accordance with the provisions of

NFPA 13 or listed or approved by a recognized testing laboratory are acceptable for sprinkler
installations.
All necessary supports for pipe work shall be supplied and fitted by the contractor.
All pipe supports must be allowed to swing freely to permit expansion and contraction of the
pipe work and shall ensure correct alignment of the services at all times.
When determining the position, design and type of brackets, care should be exercised to
ensure that ample clearance is allowed from walls and steelwork.
All brackets must be securely clamped to building structural steel. Welding to or cutting the
structural steelwork will not be permitted under any circumstances.
Where water based fire protection systems are required to be protected against damage from
earthquakes, the requirements of NFPA 13 shall be applied.

All rights reserved

4.4. Sprinkler Heads

Standard response sprinkler heads shall be installed. For European installations, sprinklers
rated as per paragraph 3.1 of DN 15, DN 20 orifice or ELO 231 sprinkler heads can be utilized.
Large drop sprinkler heads shall not be used.
4.5. Inspector Test Valves

A DN 25 (1“) test connection shall be provided on the most hydraulically remote point of the
system. A DN 25 (1“) ball valve located at 1500 mm (60 in) above finished floor equipped with a
sprinkler orifice of the same size as the system sprinklers.
Where the discharge from the test connection cannot be observed, a site glass shall be
installed.
4.6. System Drainage
All sprinkler pipework shall be sloped to drain back to the main riser to allow drainage of the
entire system from the alarm valve main drain connection. Auxiliary drains shall be provided per
the requirements of NFPA 13.
4.7. Hose Systems

Inside hose stations connected to the sprinkler system shall be installed so that two hose
streams will reach any point. Inside hose stations shall be equipped with 30 m (100 ft.) of 37
mm (1 ½ in.) fire hose or DN 25 for European installations. An adjustable fog nozzle shall also
be provided and installed for each hose station.
- Feed lines for inside hose stations shall be sized in accordance with the provisions
of NFPA 13 Section 8.16.5
- Inside hose stations shall be provided on all levels.
- Inside hose stations shall be fed from the building sprinkler systems.
- All hose stream demand shall be added to the calculations at the base of the riser
2( 2
{for 5-14 L/min/m 0.1 – 0.35 gpm/ft ) systems or less– use 1890 lpm (500 gpm);
2 2
above 14 L/min/m .( 0.35 gpm/ ft ) systems – use 3800 L/min (1000 gpm)}
- Feed lines for the hose reels shall be connected to sprinkler pipework not less
than DN 100 (2 in)
Next to the sprinkler pipe, outlets shut-off valves may be installed in the feed
lines. Coupling for hose reels shall be DN 50 (2 in).
The hose reel cabinets shall be allocated to the respective sprinkler groups according to their
location.
- In case of sprinkler groups on two levels, the hose reel cabinets shall be provided
on both levels with flow indicators.
- Hose allowance for inside cabinets is 380 L/min (100 gpm) at the end of the
application area for all systems.
2
- Hose allowance for hydrants require 3.8 L/min (1 gpm) 24L/min/m systems and
1.5 L/min (0.4 gpm) for all others added at the lead in connection to the fire loop.
4.8. Sprinklers Below Obstructions

Pipe sizing according to NFPA-schedule for sprinklers below obstructions (conveyors,
platforms, etc.)
All rights reserved

Ordinary Hazard Extra Hazard

Occupancies, OH Occupancies, XH
Diameter Maximum Maximum
1“ DN 25 2 Sprinkler 1 Sprinkler
11/4“ DN 32 3 Sprinkler 2 Sprinkler
2“ DN 50 10 Sprinkler 8 Sprinkler
The connection point for the above sprinklers should be at a pipe two sizes larger in the pipe
schedule. Sprinkler spacing must be based in NFPA 13 requirements.
Installations that exceed the maximum quantities listed in the above table shall be hydraulically
designed. Working drawings for all pipe schedule sprinkler modifications shall be submitted to
XLGAPS for field review at the subsequent Loss Prevention Survey.
NOTE: 20 sprinkler for OH and 15 sprinkler for XH as given in the above table
represent the total area that can be covered on a pipe schedule basis. If the number of
sprinkler heads under platforms, obstruction, etc. exceeds those given in the table, the
proposed extension of the sprinkler system needs to be hydraulically designed.
Grated metal mezzanines and solid noncombustible platforms that exceeds1,2 m (4 ft):
A Where employees are working or there are production operations or storage

arrangements, extend automatic sprinklers to protect below/within these areas.
B Automatic sprinkler protection is not required in the following areas:
- Below platforms, mezzanines, screen guarding, conveyors, and dust shields
without walls over single and multiple wide conveyors which is utilized for
metal bodies
- Below screen guard if the mesh thickness is below 8,38mm (.33 in) and
openings equal or greater than 50mm x 100mm ( 2 in x 4 in )
5. APPENDIX A -REQUIREMENTS FOR APPROVAL
The following active and passive fire protection measurements are subject to review and comment by
XLGAPS prior to installation and respective documentation shall be submitted:
1. Sprinkler and deluge systems 9. Underground piping and equipment
2. Inside hose connections 10. All fuel-fired equipment
3. CO2 extinguishing systems 11. Dryer and incinerator air flow system
4. Fire alarm systems 12. Filter material specification
5. Fire walls and partitions 13. Paint repair operations
6. Roof and wall construction 14. Flammable and combustible liquids in
7. Detection systems mixing, dispensing and storage
8. Connection of sprinkler systems 15. Chemicals
to the fire main
All rights reserved

Following detailed information shall be submitted:
For 1,3,8,9 :
Complete bill of materials
A. Plan layout of the piping showing
 pipe diameters sprinkler/CO2 head location with type of head used
 pipe hanger location with type of hanger used at each location
 hydraulically most remote area for calculations must be outlined
 location of inspectors test connection
B. Plan showing one or more section views of the building
C. Plan showing isometrics in order to follow up on hydraulic calculation

It is also acceptable to show calculation reference points on the
installation drawing.
D. One set of hydraulic calculation for each sprinkler/CO2 system
Reference points used in the hydraulic calculation must be either shown on an isometric drawing or the
installation drawing.
For 2 Drawing with the location and connection points to sprinkler systems
For 4,7 System specification, component layout , location, wiring diagram
For 5,6 Drawing with location and facility operation, cross section and construction,
exposures around, interior and exterior construction materials.
For 7 Facility water demand, pipe layout with valves etc,

Trenching depth of bury, filling
For 12 Data sheet, classification
For 14,15 Ventilation, grounding, electric classification, dike, cut offs

Construction specifications, amount and type (data sheet) of liquids and
chemicals to be stored.
For 10,11 Mechanical equipment drawings, Hard wire diagram, air flow diagram, purge
time, heat source, material list, PLC logic.
For 13 Ventilation rate/ducts/filter/drawings, amount and type (data sheet) of paint

being used, safety interlocks, electrical classification
5.1. Spray Booth Electrical Classification

US Installations European Installations
Location Powder Solvent borne Solvent borne Waterborne
& Waterborne
All rights reserved

Plenum (no re circulation) NA Unclassified Unclassified Unclassified

Plenum (re circulation) Unclassified Class 1, Div. 1 Class 1 Zone 1 Class 1 Zone 2
Scrubber (collector) Class 2, Div.1 Class 1, Div.1 Class 1 Zone 1 Class 1 Zone 2
Inside spray booth, rotary Class 2, Div.1 Class 1, Div.1 Class 1 Zone 1 Class 1 Zone 2
machine cabinet, robot
cat-trac enclosure and
exhaust ductwork
Air supply house Unclassified Unclassified Unclassified Unclassified
Recirculation filter house Class 2, Div.1 Class 1, Div.1 Class 1 Zone 1 Class 1 Zone 2
Color changer NA Class 1, Div.1 Class 1 Zone 1 Class 1 Zone 2
3 ft /1 m rule around Class 2, Div. 2 Class 1, Div. 2 Class 1 Zone 2 Unclassified
openings to Class 1, Div.1
The paint shop building areas, outside of classified processes, are considered to be
unclassified.
Application of Class IIIB combustible liquid (Flashpoint > 93°C) can be performed in
unclassified locations.
5.2. Connection of paint lines to the spray booth
The use of plastic paint lines for all types of paints outside of the spray booth, color changers
located external to the booth, cat track, or hose cabinets is not permitted. Exception: PTFE
flexible pipe covered by one layer wire braid, stainless steel has been accepted for the use in
waterborne paint supply lines. Flexible pipe shall be no larger than 12 mm (0.5 inch) diameter,
properly supported and protected from damage by the use of cable trays or equivalent.
5.3. Rotary Atomizer (Esta) Machine Cabinets
The cabinets for the side machines and the supports for the roof machines shall be arranged as
follows:
a) Electrical classification shall be as shown in the following table:
US Installations European Installations

Powder Solventborne & Solventborne Waterborne
Waterborne
Class 2, Div.1 Class 1, Div.1 Class 1 Zone 1 Class 1 Zone 2
b) If the cabinets meet the requirements of NFPA 496 “Purged and Pressurized Enclosures
For Electrical Equipment”, classification within the cabinets may be reduced to unclassified.
c) The bottom of the cabinets shall be closed liquid tight.
d) For liquid paints, the cabinets shall overflow to the spray booth water wash system. The
ventilation openings at the bottom may be used for this purpose. For powder paints, a drain
to a safe location shall be provided.
e) For liquid paints, the paint lines shall be rigid tubing up to the bottom of the cabinets (see
paragraph 5.2 for exception for use of flexible tubing). For powder paint, the powder hose
shall be supported and protected from damage by the use of cable trays or equivalent.

All rights reserved

5.4. Deluge system discharge test in electrostatic painting (ESTA) zones

If the fire protection contractor can demonstrate on the design drawings that the location of the
deluge heads will provide complete coverage wetting all equipment in the protected zone then
the discharge test can be modified as follows:
Install pipe extensions from the head connections to the booth grating level and trip the system
to assure that water flow is attained
Special attention must be given to rotary atomizer (ESTA) stations with traveling overhead
machines to assure that all areas are covered at all possible locations of the overhead machine.
5.5. Fork lift classification for paint mix and storage room
Paint Storage Rooms:
For GME plants, EX-rated forklifts are not required for paint drum transportation in and out of a
storage room. This regulation shall apply unless local regulations/laws have other requirements
for forklifts.
For GMNA plants, power operated trucks shall not be permitted within storage rooms, unless
they are battery powered units listed or approved as EE trucks.
Paint Mix Rooms:

For GME plants, protection requirements for Zone 1 (Class I, Div.I, Group D) shall be met.
For GMNA Plants, power operated trucks shall not be permitted within dispensing and mixing
rooms unless they are approved explosion proof battery powered units listed or approved by as
EX trucks.
5.6. Paint Mix and Storage Rooms – Tote and Mix Container Venting
Paint mix tanks and connected supply totes are considered process vessels when referring to
NFPA 30.
Containers shall be vented directly to the room atmosphere with a flame arrestor. A
combination flame arrestor/conservation vent may be used dependent upon process
requirements.
Exception: Containers holding isocyanate materials shall be vented to atmosphere exterior of
the building. A flame arrestor or a combination flame arrestor/conservation vent shall be used
Ventilation shall be provided per the requirements of paragraphs 3.27 and 3.28.
Ventilation shall be supervised with an audible and visual local alarm to assure its continuous
operation. Supervision must be accomplished by the use of a pressure differential switch(s) or
airflow device(s).
5.7. Rotary atomizer (ESTA) stations
Door exits from the rotary atomizer (ESTA) station shall be spaced not more than 23 m (75 ft)
apart from each side of the conveyor. Travel through a door in a silhouette is acceptable if the
doors swing out from the inside the rotary atomizer zone. In the case where two or more
stations are located back to back, doors on each side shall be provided between overhead
machines to allow path to safety when both overhead machines are lowered. Doors shall be a
minimum of 810 mm (32 in).
5.8. Paint line flushing

All rights reserved

An inert gas, such as nitrogen, shall be used for the blow back of all paint (solvent borne and
waterborne) and solvent lines. The inert gas supply pressure shall not exceed the maximum
recommended pressure for the circulation system piping. For initial cleaning, all operations in
the paint shop shall be shutdown due to the possibility of leaks. Initial flushing of paint lines
using materials with a flash point greater than 93 C (200F) may be accomplished with air.
5.9. Twin tank systems for colored primer coat (waterborne primer)
If paints are classified as non-burning or non self-sustaining burning (according PTB triangle
test), the following protection features are needed:
 enclosed by sheet metal
 provide spill containment
 mechanical ventilation to remove vapors on the basis of 6 air changes per hour
 classified electrical equipment - Zone 2 or class I, division 2
(Electrical classification shall be Zone 1or class I division 1 for solvent based paints)
 sprinkler protection designed for 24 L/min/m² (0.60 gpm/ft ) over entire area
2
 proper housekeeping
 maximum paint storage 82 L/m² (2 gal/ ft )
2
 proper bonding and grounding

5.10. Mixing and Dispensing of Class I and II Flammable Liquids
Liquids Class I with flash point below 37 °C(100°F)
Liquids Class II with flash point 37° C till 60°C(100-140 °F)
a) Class I liquids shall not be stored, handled or used in basements

b) Small flammable & combustible liquid mixing rooms:
2 2
If the storage room floor area is 14 m (150 ft ) or less, the requirements according to NFPA
33, Ch.6.3.2 for rooms are:
 enclosed by sheet metal
 provide spill containment
 mechanical ventilation to remove vapors on basis of 6 air changes per hour
 classified electrical equipment- Zone 1 or Class 1, Div. I

2
sprinkler density 24 L/min/m². (0.60 gpm/ft )
 proper housekeeping

2 2
maximum paint storage 82 L/m (2 gal/ft )
 proper bonding and grounding
c) Local Dispensing
Local dispensing systems limited to two metal drums (200 liters each) with one dispensing
and one standby are permitted if
 flash point is above 37C (100F)
 spill containment and sprinkler protection is provided
Note: Enclosure and special electrical classification are not required. If the flash point of the
material is below 37C (100F) refer to the requirements of small flammable &
combustible liquid mixing rooms.
2 2
e) For storage and dispensing operations larger than 14 m (150 ft ), refer to requirements for
paint mix rooms.
5.11. Mixing and Dispensing of Class III Combustible Liquids

All rights reserved

a) Class IIIA Liquids – flashpoint between 60 – 93C (140 - 200F)

Quantities up to 2 portable tanks each not exceeding 2500 liters (660 gallons) do not require
additional protection features other than:
 spill containment
 separation from other operations by distance
 natural or mechanical ventilation
Quantities in excess of the above limits shall be limited to operation for one continuous 24
hour period. Otherwise, chapter 2 and section 5-3 of NFPA 30 shall be applied.
b) Class IIIB Liquids – flashpoint above 93C (200F)
Quantities up to 20 portable tanks each not exceeding 2500 liters (660 gallons) do not
require additional protection features other than:
 spill containment
 separation from other operations by distance
 natural or mechanical ventilation
5.12. Storage room of flammable and combustible liquids
Class I, II and III A liquids shall be stored in separate cut-off areas.

Cut-off area = F-90 construction.
a) Storage of Class I,II,III A liquids up to 450 liters. (120 gal).

 shall be stored in a UL listed or FM approved storage cabinet
 cabinets are not required to be vented
 cabinets should be labeled
 assure spill containment
 no EX zone around
b) Inside storage rooms - Class I, II, III A liquids (more than 450 liters (120 gal).)
(None of the walls is an exterior wall)

 floor area cannot exceed 45 m²

2
metal panel wall on steel is needed for floor area less than 14 m² (150 ft )

2
F-90 cut-off needed for floor area between 14 - 45 m² (150-485 ft )
 exhaust ventilation approx. 15 cm (6 in)above floor
 mechanical ventilation shall be 6 air changes per hour
 spill containment (ramp, curb at door openings)
 electrical suitable for Class 1, div. II or Zone 2 in Germany
 non smoking“ within a distance of 5m (16 ft) from the door
 class I and II liquids should not be stored more than 1 container high
 sprinkler protection:
2 2
2 2
Temperature rating Ordinary (57-77 C ) Ordinary (135-170 F)

All rights reserved

2 2
Area of application Entire room (max. 372 m ) Entire room (4,000 ft )
For rack storage in-rack sprinkler at each level may be required.

 Storage limitations for rooms  14 m²( 150 ft ) = 192 L/m²( 4.75 gal/ft )
2 2

2
Storage limitations for room 14 m² to 45 m² (150-485 ft )= 385 L/m²
c) Attached or cut-off rooms - Class I, II and IIIA liquids (more than 450 liters (120 gal)).
(Attached room = 3 or more walls are exterior walls

cut-off room = less than 3 or more walls are exterior walls)
 floor area is not restricted


2
F-60 cut-off needed for floor area less than 27 m²(290 ft )

2
F-90 cut-off needed for floor area more than 27 m²(290 ft )
 exhaust ventilation approx. 15 cm (6 in)above floor
 mechanical ventilation shall be 6 air changes per hour
 spill containment (ramp, curb at door openings)
 electrical suitable for Class 1, div. II or Zone 2 in Germany
 “non smoking“ within a distance of 5m(16 ft) from the door
 sprinkler protection:
2 2
2 2
Sprinkler spacing 9.3 m 100 ft
Temperature rating Ordinary (57-77 C ) Ordinary (135-170 F)
2 2
Area of application Entire (max. 372 m ) Entire (max 4,000 ft )
d) Class III B liquids above 93°C (200°F)
No additional protection features needed

 storage in general purposes warehouse allowed if automatic sprinkler installed
 storage in productions areas allowed but drip pan suggested
 maximum quantity 52.000liters (13,000 gal). and maximum high 4,5 m (15 ft)
e) Requirements for physical separation (attached or cut-off)

 room size between 14 and 93 m² (150-1000 ft )- F-60 rated walls needed
2

2
room size more than 93 m² (1000 ft )- F-120 rated walls needed
5.13. Explosion Venting

All rights reserved

Provision shall be made for explosion venting in all areas designated as catastrophic hazards and in
other areas where combustible or explosive atmospheres of vapor or dust may develop. Venting shall
be provided by means of roof ventilators, side wall panels or sach attached with dead soft copper clips
or other means approved by the fire underwriters. These methods are recommended in lieu of glass
scoring. Panels or sash may be arranged to swing or fall open due to explosion pressures in the range
of 96 Kpa (20 psf).
2 2 3 3
Generally, the minimum vent area shall be 0,09 m (1 ft ) of effective vent area to 0,28 m (10 ft ) of
room volume for very small rooms up to 1 to 50 for large rooms such as paint mixing or similar areas
3 3
over 710 m (25.000 ft ) in volume.
 if required vent area is  available vent area, the entire outside wall should provide
means of explosion relief
Documentation for explosion venting, including calculation and means of explosion venting,
shall be submitted to XLGAPS for review.

All rights reserved

6. APPENDIX B
THIS SECTION PROVIDES ADDITIONAL FIRE PROTECTION INFORMATION FOR
ROTARY ATOMIZER AND ELECTROSTATIC ROBOTIC STATIONS
Refer to Appendix C - Logic Diagram 3 for System Operation
6.1 Overhead Machine CO2 system
GMNA Facilities
 CO2 supply shall be liquid from CO2 supply container with capacity supervision.
 A 34% concentration of CO2 shall be achieved within one minute after agent release.
Once a concentration of 34% is achieved, it must be held for one additional minute. A
minimum of two shots must be available.
 Actuation is by optical flame detectors or linear heat detection inside the roof bar.
GME Facilities
 CO2 supply shall be gaseous from CO2 supply container using a solenoid valve and
with capacity supervision.
Once a concentration of 34% is achieved, it must be held for one additional minute. A
minimum of two shots must be available.
 Actuation is by optical flame detectors inside the roof bar and by detectors inside the
booth, which are directed to supervise the rotary atomizers (bells) of the roof machine.
6.2 Cabinet CO2 system
 CO2 supply is liquid
Once a concentration of 34% is achieved, it shall be held for one additional minute. A
minimum of two shots shall be available.
 Actuation is by the cabinet optical flame detectors or linear heat detection.
 Rotary atomizer stations with the color changer located on the extension arm shall have
an optical flame detector or linear detection placed in the arm. A CO2 nozzle is not
required in the arm if it is open to the side cabinet.
CO2 is not required for cat-trac enclosure area of current GMNA approved robotic systems
when the cables for servomotors and electrostatic power are listed for use with solvents
normally used in painting operations.
6.4 Deluge System
 A flame detected by one optical flame detector will result in shutting down the spray
process. If after a 10 second delay, a flame is detected by two booth optical flame
detectors the deluge valve for the affected zone shall be operated.
 If spray shutdown capability is not provided, the deluge shall be discharged immediately
after a flame is detected by two booth optical flame detectors.
6.5 Sprinkler System

2
The general booth shall be protected by sprinklers with a design density of 14 L/min/m
2
(0.35 gpm/ft ).
 The electrostatic zones shall be protected with a deluge system with a design density of
2 2
24 L/min/m (0.60 gpm/ft ).

All rights reserved

 Manual operation of CO2 and deluge systems shall be from booth operating level.
 Booth sprinkler protection shall be extended to cover all side and overhead support
cabinets.
 For rail mounted robots, the booth sprinkler protection shall be extended to cover all
rail, color changer and cat-trac enclosures.
7. APPENDIX C – LOGIC DIAGRAMS
PAINT APPLICATIONS USING:

1) NON-ELECTROSTATIC (MANUAL AND AUTOMATIC)
2) ELECTROSTATIC (MANUAL AND AUTOMATIC)
3) NON-ELECTROSTATIC APPROVED ROBOTIC (WATERBORNE/SOLVENT)
(SLUDGE REMOVAL WATER, AIR SUPPLY AND EXHAUST SHALL

REMAIN ON ALL TIMES EXCEPT AS NOTED IN TEXT)
NOTE A: FIRE INTERLOCK SHUTS NOTE B: DESIGN
GENERAL MONITORING
OFF 1)CONVEYERS, 2)AUTOMATIC DENSITY OF 0.35
PAINT SYSTEM EQUIPMENT AND GPM/SQ.FT. FOR
FIRE INTERLOCK
3)HIGH VOLTAGE ENTIRE BOOTH AREA
SHUT DOWNS
AFFECTED. (EXISTING
BOOTHS WITH EXTRA
HAZARD SPRINKLER
PROTECTION ARE
ACCEPTABLE)
PROPRIETARY FIRE ALARM
OPERATE FIRE INTERLOCK

ALARM TO PROPRIETARY
SHUT DOWN ALL PAINT &

THINNER SUPPLY PUMPS
SPECIALTY/SATELLITE
FIRE ALARM SYSTEM
TROUBLE SIGNAL TO
(SEE NOTE A)
(INCLUDES
SYSTEMS)
SYSTEM
DEVICE EVENT
SPRINKLER PROTECTION 1 ST SPRINKLER OPERATED X X X
(SEE NOTE B) O S & Y VALVE CLOSED X

PAINT PUMP STOP EMERGENCY
PAINT PUMPS X X X
RELAY MANUAL TRIP
7.1. DIAGRAM 1

All rights reserved

7.2. DIAGRAM 2
This diagram is for reference only. It shall not apply to new installations unless prior approved is
given by the responsible GM operating group and GM Security.

All rights reserved

7.3. DIAGRAM 3

All rights reserved

7.4. DIAGRAM 4

All rights reserved

7.5. DIAGRAM 5
Fire Protection Requirement for Plastic Canopies, Tunnels and Enclosures
Area Served Sprinklers No Sprinklers

Canopies Single line X
Multiple lines and product X
completely non-combustible
Multiple lines and product with X
combustible panels
Combustible storage X
Enclosures and Single line with no manual X

Tunnels operations
Single or multiple lines with X
manual operations
Multiple lines and product with X
combustible parts
Multiple lines and product X
completely non-combustible
and no manual operations

All rights reserved

8. REVISION HISTORY
Date: Change Control No.: Revision: Reason/Need:
15 AU08 003-08 D 2008 Update
- Commonized units of measure with Global Security Fire Protection and Prevention
Specification.
- Modified sprinkler spacings and araeas of application to conform to revised Global
Security Fire Protection Specification.
- 3.6 Eliminated the provisions for CO2 to shaping air supply for fire supression.
- 3.16 clarified that the bake lamps are not required to be interlocked with ventilation.
- 3.18 added tacky mesh to plastic tunnels
- 3.27, 3-28 clarified paint mix room ventilation alarm /Allows use of direct fired gas
burner if certain conditions are met. / Revised the design air changes per hour from 12
to 6/ Provides option to use wet sprinkler with containment in lieue of CO2 fire
supression system for paint mix rooms.
- 3.8 Clarified the use of a single sprinkler to protect robot cat trak
- 5.1 add Class IIIB liquid clarification
- 3.5 add laminated glass as a option
- 3.22 hydrocarbon calibration gas
- Modified diagram 3 to remove CO2 discharge through shaping air .

All rights reserved

GENERAL MOTORS GLOBAL SECURITY MANUAL
FIRE PREVENTION PROTECTION SECTION
CHAPTER 14
Diagram 1
PROCESS FIRE PROTECTION SYSTEMS LOGIC DIAGRAM #1
PAINT APPLICATIONS USING:

1) NON-ELECTROSTATIC (MANUAL AND AUTOMATIC)
2) ELECTROSTATIC (MANUAL AND AUTOMATIC)
3) NON-ELECTROSTATIC APPROVED ROBOTIC (WATERBORNE/SOLVENT)

NOTE A: FIRE INTERLOCK SHUTS NOTE B: DESIGN
GENERAL MONITORING
OFF 1)CONVEYERS, 2)AUTOMATIC DENSITY OF 0.35
PAINT SYSTEM EQUIPMENT AND GPM/SQ.FT. FOR
FIRE INTERLOCK
3)HIGH VOLTAGE ENTIRE BOOTH AREA
SHUT DOWNS
AFFECTED. (EXISTING
BOOTHS WITH EXTRA
HAZARD SPRINKLER
PROTECTION ARE
ACCEPTABLE)
PROPRIETARY FIRE ALARM
OPERATE FIRE INTERLOCK

ALARM TO PROPRIETARY
SHUT DOWN ALL PAINT &

THINNER SUPPLY PUMPS
SPECIALTY/SATELLITE
FIRE ALARM SYSTEM
TROUBLE SIGNAL TO
(SEE NOTE A)
(INCLUDES
SYSTEMS)
SYSTEM
DEVICE EVENT
SPRINKLER PROTECTION 1 ST SPRINKLER OPERATED X X X
(SEE NOTE B) O S & Y VALVE CLOSED X

PAINT PUMPS X X X
RELAY MANUAL TRIP
October 31, 20001

GENERAL MOTORS GLOBAL SECURITY MANUAL
FIRE PREVENTION PROTECTION SECTI
CHAPTER 14
Diagram 2
FOR PAINT BOOTH APPLICATIONS USING
1) NON-ROBOTIC ELECTROSTATIC ROTARY ATOMIZERS

2) ROBOTIC ELECTROSTATIC ROTARY ATOMIZERS
3) ROBOTIC ELECTROSTATIC NON-ROTARY ATOMIZERS
4) NON-APPROVED ROBOTIC

ALARMS & LOCAL ALARMS

GENERAL MONITORING
FIRE CONTROL PANEL
FIRE PROTECTION
FIRE INTERLOCK
NOTE A: FIRE INTERLOCK
SHUT DOWNS
SHUTS OFF 1)CONVEYORS,
2)ROBOT UNITS, 3)AUTOMATIC
PAINT SYSTEM EQUIPMENT,
4)HIGH VOLTAGE AND
5)CONTROL AIR
LOCAL AUDIBLE TROUBLE SIGNAL AT FIRE CONTROL
ALARM HORN/STROBES AT AFFECTED BOOTH ONLY

TROUBLE ANNUNCIATOR AT FIRE CONTROL PANEL
FIRE CONTROL PANEL POWER (GREEN LIGHT) OFF-

LOCAL AUDIBLE ALARM AT FIRE CONTROL PANEL
SHUT DOWN ALL PAINT & THINNER SUPPLY PUMPS

ALARM HORN/STROBES INSIDE AFFECTED BOOTH
ROTARY-BY ZONE & BOOTH/MODULAR-BY BOOTH
ALARM ANNUNCIATOR AT FIRE CONTROL PANEL
TROUBLE SIGNAL TO PROPRIETARY FIRE ALARM
OPERATE DELUGE VALVE IN AFFECTED ZONE OR

DISCHARGE CO 2 IN AFFECTED ZONE OR BOOTH
ALARM TO PROPRIETARY FIRE ALARM SYSTEM
(INCLUDES SPECIALTY/SATELLITE SYSTEMS)
OPERATE FIRE INTERLOCK (SEE NOTE A)

TRANSFERS TO STANDBY BATTERIES
SYSTEM
BOOTH
PANEL
ONLY
DEVICE EVENT
DETECTION SYSTEM
TUBING
RUPTURE BREAK X X X X X X X X
LOW PRESSURE
CO2 DETECTION SYSTEM
LOW LIGHT LEVEL
X X X
LEVEL 1 CO2 SYSTEM MANUAL TRIP X X X X X X X X

DETECTION
CO2 SYSTEM TUBING LOW X X X
PRESSURE
1 ST DETECTOR OPERATED X X X
DELUGE 2 ND DETECTOR OPERATED X X X X X X X X

Flame Detetctor
DETECTOR
Supervision
x X
MANUAL TRIP
LEVEL 2 DELUGE VALVE
PULLED
X X X X X X X X
O S & Y VALVE CLOSED X X X

PAINT PUMPS
RELAY MANUAL TRIP
X X X X X X X
FIRE SYSTEM TROUBLE OUTSIDE

COMPONENT PANEL
X X X
FIRE CONTROL
OTHER
PANEL
AC FAILURE X X
FIRE CONTROL CIRCUIT TROUBLE

PANEL INSIDE PANEL
X X X
BOOTH WET SPRINKLERS OPERATED X X X X X X
October 31, 2001

FOR NEW PAINT BOOTH APPLICATION USING:
1) NON ROBOTIC ELECTROSTATIC ROTARY ATOMIZER
2) ROBOTIC ELECTROSTATIC
3) ROTARY ATOMIZER AND/OR NONROTARY SPRAYING EQUIPMENT
4) NON-APPROVED ROBOTIC
Fire control panel Shut

General monitoring alarms + local alarms downs
Alarm horn and Flashing

Audible alarm to control
CO2 Discharge with 34%
Alarm to proprietary fire

CO2 - System - Level 1
light1) at affected booth
thinner supply @ paint

Switch over to battery
Trouble to proprietary
applicator shaping air
control system (FMC)
Shut down all paint +

(min. 24h capacity)
Paintshop process
Audible trouble to
fire alarm system
CO2 Discharge to
alarm system
control panel
Fire interlock
for 1 minute
mix room
panel
Device Event
Flame detection Detect flame on applicator (identical with
system first line deluge system)
X X X X X X
Detect flame in side and roof machine
(single line arrangement)
X X X X X X X
2)
Flame detector supervision X X
Fire control panel 3) Power failure X X X
Door open X X
CO2 system Manual trip at each booth door X X X X X X X
CO2 pressure switch (auto & man) X X X X X X
Container quantity supervision X X
Paint & thinner stop
relay
Emergency manual trip X X X X X X
Fire control panel Shut downs

General monitoring alarms + local alarms
Alarm horn and Flashing

Audible alarm to control
Alarm to proprietary fire
Operate deluge valve in
Deluge - System - Level 2

light1) at affected booth
thinner supply @ paint

Switch over to battery
Trouble to proprietary
control system (FMC)

(min. 24h capacity)
Paintshop process
Audible trouble to
fire alarm system
thinner supply @
affected booth
affected booth
alarm system
control panel
Fire interlock
mix room
panel
Device Event
4)
Flame detection 1st. line detection X X X X
system 2nd. line detection X X X X X X X X
2)
Flame detector supervision X X X
Fire control panel 3) Power failure X X X
Door open X X
Deluge system Gate valve closed X X
Manual trip at each booth door X X X X X X X X
Mechanical actuation at deluge valve X X X X X X X X
Alarm pressure, switch / deluge valve X
Paint & thinner stop
relay (process)
Emergency manual trip X X X X X X
Wet Sprinklers Operated x x x x x
Sludge removal water, air supply, bearing air 1) to be seen inside booth
and exhaust shall remain on all times, except 2) cable break and flame eye supervision
as noted in text (entire circuit from flame detector lens
to local alarm panel)
Fire Interlock Shuts Down 3) no release if local panel door is open
- high voltage 4) time delay < or = 15 sec. (see below)
- conveyor
- control- and drive air 2. Detector Deluge
- robot units 1. Detector Discharge
- automatic paint system equipment
0 3 6 9 12 15 sec.
October 31, 2001

FOR POWDER PAINT BOOTH APPLICATIONS USING AUTOMATIC EQUIPMENT
1) APPROVED ROBOTIC AND NON-ROBOTIC
ALARMS & LOCAL ALARMS

GENERAL MONITORING
FIRE CONTROL PANEL
FIRE INTERLOCK
NOTE A: FIRE INTERLOCK
SHUTS OFF 1)CONVEYERS,
2)AIR SUPPLY UNITS,
3)EXHAUST FANS, 4)PAINT
SUPPLY, 5)AUTOMATIC PAINT
SYSTEM EQUIPMENT, 6)HIGH
VOLTAGE AND 7)CONTROL AIR
ALARM TO PROPRIETARY FIRE ALARM SYSTEM
ALARM HORNS/STROBES INSIDE AND OUTSIDE

OPERATE DELUGE VALVE AT AFFECTED ZONE
PROGRAMMABLE CONTROLLER (SEE NOTE A)

TROUBLE ANNUNCIATOR AT FIRE CONTROL
LOCAL AUDIBLE TROUBLE SIGNAL AT FIRE

LOCAL AUDIBLE ALARM AT FIRE CONTROL
ALARM ANNUNCIATOR AT FIRE CONTROL
TROUBLE SIGNAL TO PROPRIETARY FIRE
OPERATE FIRE INTERLOCK ON

AFFECTED BOOTH
CONTROL PANEL
ALARM SYSTEM
OR BOOTH
PANEL
PANEL
DEVICE EVENT PANEL
LEVEL 1 1 ST DETECTOR OPERATED X X X
2 ND DETECTOR OPERATED X X X X X X
FLAME DETECTOR
DETECTOR
SUPERVISION
X X X
LEVEL 2 1 ST SPRINKLER OPERATED X X X X X

Preaction O S & Y VALVE CLOSED X X X
MECHANICAL
ACTUATION AT X X X X X X
DELUGE VALVE
EMERGENCY
SYSTEM STOP
MANUAL TRIP
X X X
FIRE SYSTEMS TROUBLE OUTSIDE

OTHER
COMPONENT PANEL
X X X
FIRE CONTROL
PANEL
AC FAILURE X
FIRE CONTROL TROUBLE INSIDE
PANEL PANEL
X X X
DETECTOR OPERATED X X X X X
POWDER COLLECTION FIRE SUPPRESSION TROUBLE OUTSIDE

EQUIPMENT SYSTEM CONTROL PANEL
X X X
SUPPRESSION
SYSTEM CONTROL AC FAILURE X X X
PANEL
SUPPRESSION
TROUBLE INSIDE
SYSTEM CONTROL
PANEL
X X X
PANEL
October 31, 2001

Table 3.0-a – General Sprinkler Protection Requirements
Sprinkler Maximum Hose

Area of Maximum
Density Area per Allowance
Occupancy Application Sprinkler
Sprinkler gpm
gpm/ft
2 Head Spacing
2
2
ft (m )
2 2 2
ft (m ) System (L/min)
(L/min/m ) 2 2
ft (m )
Light Hazard/Offices, Including 52,000 500

0.10 (4) 3,000 (279) 130 (12) 1
Data Processing (4,836) (1,890)
Contiguous Press Shop 2 – first
52,000 500
floor 0.20 (8) 3 2,000 (186) 3 130 (12)
(4,836) (1,890)
& Body Shop (limited storage)
52,000 500
Press Basement 0.30 (12) 3,000 (279) 100 (9.3)
(4,836) (1,890)
Ordinary Manufacturing 52,000 500

0.30 (12) 4 4,000 (372) 130 (12)
(machining) (4,836) (1,890)
Paint Shop Operations
52,000 500
(excluding mix and storage 0.30 (12) 3,000 (279) 130 (12)
(4,836) (1,890)
rooms)
40,000 750
Paint Mix and Storage 0.60 (24) 3,000 (279) 100 (9.3)
(3,716) (2,840)
40,000 750
General Assembly 15 0.40 (16) 4,000 (372) 100 (9.3)
(3,716) (2,840)
40,000 750
General Assembly 26 0.60 (24) 3,000 (279) 100 (9.3)
(3,716) (2,840)
Production Paint Spray Booths
750
& Ovens where protection is 0.35 (14.3) N/A 90 (8.4) N/A
(2,840)
needed
Notes:
1 In open office areas that are cut off from adjacent occupancies by a minimum 1 hour fire partition AND have a smooth ceiling;
2 2 2 2
maximum spacing of 225 ft (21 m ) is acceptable. Head spacing in excess of 225 ft (21 m ) requires advance approval from Global
2 2
Security. Under no circumstances may the head spacing exceed 400 ft (37.2 m ).
2 Sprinkler protection for the operating floor of the press shop may be waived, subject to the approval of the authority having jurisdiction.
3 An increase in the required density and area of application may be warranted in areas where storage is such that the given density
and area of application would be considered insufficient.
2 2
4 Storage in these areas must be limited to 10 ft. (3 m) high, 500 ft (45 m ) piles. If this combustible loading is exceeded, sprinkler
2 2 2 2
densities should be increased to 0.60 gpm/ft (24 L/min/m ) over any including the hydraulically most remote 4,000 ft (372 m ).
2 2
5 Storage must be limited to 15 ft. (4.6 m) high, 1000 ft (93 m ) piles. In addition, screenguarding must be limited and protection
provided beneath where required.
6 These requirements apply where the storage limitations of Note 5 cannot be met, or where extensive screenguarding is present or
expected.
Table 3.0-b GM Owned or Leased Facilities
100,001-350,000 ft2 (9300-32550m2)
FIRE PROTECTION REQUIREMENTS COMMENTS

CATEGORY
Water supply One source calculated to highest Additional source may be required (if
WATER sprinkler/hose stream demand exposure warrants)
SUPPLIES Two fire pumps each sized NFPA 20 Public supply may be acceptable
according to system hydraulic alternative to supply hydraulic
demand demand
Duration of water supply 120 minutes Each source
Water distribution 100,001-200,000 ft2—U Loop Sprinkler hydraulic demand may

>200,000 ft2—Complete Loop require larger than 8” (200 mm)
minimum
Hydrants NFPA 24 500 ft (152 m) spacing
Office occupancies 0.10/3,000 100 gpm (400 L/min) Maximum sprinkler spacing 130 ft2
hose stream demand (11.9 m2) per NFPA for type of
sprinkler
Occupancies, i.e., manufacturing, 0.30/4,000; 500 gpm (1890 L/min) Maximum sprinkler spacing 130 ft2
assembly hose stream demand (11.9 m2), Ordinary combustible
storage @ 12 ft (3.4 m) maximum.
Plastic storage @ 10 ft (3 m) max-
2 2
AUTOMATIC imum with 500 ft (45 m ) piles
SPRINKLERS Occupancies, i.e., Heat treat, 0.45/4,000; 750 gpm (2839 Maximum sprinkler spacing 130 ft2
plastics, painting L/min) hose stream demand (11.9 m2)
Fixed rack storage associated GMFP&P Chapter 3 , Standard 3.6 Exposed, expanded plastic per NFPA
with manufacturing 13 + 1 additional level of in-rack
sprinklers
Warehousing, rack and bulk GMFP&P Chapter 2, Standard 3.6 Use of ELO and ESFR sprinklers
acceptable
Flammable liquids storage NFPA 30 flammable and 0.60/3,000 may be needed.
combustible liquids Deviation-Global Security
Inside hose connections NFPA 13 and 14 as appropriate Maximum spacing 1:10,000 ft2 (930
m2), two point attack for storage
Alarm system NFPA 72 & GMFP&P Chapter 5, Approved/listed central station or
BUILDING Standard 3.4 proprietary
FEATURES Fire extinguishers NFPA 10 Spacing as appropriate
Draft curtains May be required, see GMFP&P Floor openings, elevation changes,
Chapter 4, Standard 3.3 special hazards
Venting May be required, see GMFP&P Over special hazards
Firewalls, partitions May be required, see GMFP&P As required by AHJ
Chapter 4, Standard 3.3
Yard Storage GMFP&P Chapter 3 , Standard 3.6 Deviation-Global Security
Fire Department Roadway Deviation-Global Security
Roof GMFP&P Chapter 4, Standard 3.2 UL or FM requirements

Table 3.0-c GM or Supplier Owned or Leased Facilities
100,000 ft2 (9300 m2) or Less

CATEGORY
sprinkler/hose stream demand exposure warrants)
One fire pump ( sized according NFPA 20 Public supply may be acceptable
to hydraulic demand) alternative
WATER
SUPPLIES Duration of water supply 60 minutes Each source
Water distribution “L” shaped fire main with hydrants at Sprinkler hydraulic demand may
two corners Exception: Office require larger than 6-inch (150 mm)
occupancy minimum
Hydrants NFPA 24 500 ft. (152 m) spacing
Office occupancies NFPA 13, light hazard 100 gpm Maximum sprinkler spacing per NFPA
(400 L/min) hose stream demand for type of sprinkler head
Occupancies, i.e., 0.30/3,000; 250 gpm (1000 L/min) Maximum sprinkler spacing 130 ft2
manufacturing, assembly hose stream demand (11.9 m2), Ordinary combustible
storage @ 12 ft. (3.4 m) maximum.
Plastic storage @ 10 ft (3 m) max-
2 2
AUTOMATIC imum with 500 ft (45 m ) piles
SPRINKLERS Occupancies, i.e., Heat treat, 0.38/3,000; 500 gpm (1890 L/min) Maximum sprinkler spacing 130 ft2
plastics, painting hose stream demand (11.9 m2)
Fixed rack storage associated NFPA 13 Exposed, expanded plastic per NFPA
with manufacturing 13 + 1 additional level of in-rack
sprinklers
Warehousing, rack and bulk NFPA 13, Use of ELO and ESFR sprinklers
GMFP&P Chapter 2, Standard 3.6 acceptable
Flammable liquids storage NFPA 30 flammable and 0.60/3,000 may be needed. Deviation-
combustible liquids Global Security
Inside hose connections NFPA 13 and 14 as appropriate Maximum spacing 1:10,000 ft2 (930
m2), two point attack for storage
Alarm system NFPA 72 & GMFP&P Chapter 5, Approved/listed central station or
Standard 3.4 proprietary
BUILDING Fire extinguishers NFPA 10 Spacing as appropriate
FEATURES Draft curtains May be required, see GMFP&P Floor openings, elevation changes,
Chapter 4, Standard 3.3 special hazards
Venting May be required, see GMFP&P Over special hazards
Firewalls, partitions May be required, see GMFP&P As required by AHJ

Chapter 4, Standard 3.3
Yard Storage GMFP&P Chapter 3, Standard 3.6 Deviation-Global Security
Roof GMFP&P Chapter 4, Standard 4.2 UL or FM requirements
Table 3.6.3.3-a Expanded (Exposed & Cartoned) Group A Plastics (e.g.,
foam, seats, instrument panels)
Storage Sprinkler Area of Maximum Maximum Minimum

Height Density Application Pile Size Pile Size (ft2) Aisle
Width (ft)
{m2} – {m}
(ft) {m} (gpm/ft2) (ft2) {m2} (ft2) {m2} – Baskets with
Wire Metal
{L/min/m2} Baskets Partitions
10 {3} 0.3 {12.2} 4,000 {372} 500 {46.5} 500 {46.5} 10 {3}
>10 to 15 0.6 {24.4} 4,000 {372} 1,000  1500  10 {3}
{>3 to 4.6} {139.5} {139.5}
>15 to 20 0.6 {24.4} 4,000 {372} 1,000  1,500  12 {3.7}
{4.6 to 6.1} {139.5} {139.5}
>20 {6.1} NOT PERMITTED – CONTACT GM GLOBAL SECURITY
Limit baskets to 3 units wide
Limit baskets to 4 units wide

Table 3.6.3.3-b Non-Expanded Group A Plastics
(e.g. rigid plastics and tires)
Storage Sprinkler Area of Maximum Pile Minimum Aisle

Height Density Application Size Width (ft) {m}
(ft) {m} (gpm/ft2) (ft2) {m2} (ft2) {m2}
{L/min/m2}
10 {3} 0.3 {12.2}
4,000 {372} 500 {46.5} 10 {3}
>10 to 15 0.6 {24.4}
4,000 {372} 2,500  10 {3}
{>3 to 4.6} {232.5}
(see note
)
>15 to 20 0.6 {24.4} 4,000 {372} 2,500  12 {3.7}
{4.6 to 6.1} {232.5}
>20 {6.1} NOT PERMITTED – CONTACT GM GLOBAL SECURITY
Storage heights >12 ft {3.7} for tires are NOT permitted
 Prefer long, narrow piles for manual fire fighting purposes
Table 3.6.3.3-c Specific Application Sprinklers
Maximum Pile Sizes - ft2 (m2)
Class I-IV
commodities, Cartoned Cartoned Exposed Exposed
Sprinkler and Group B, C Expanded Non-Expanded Expanded Non-Expanded
Type Plastics Plastics Group A Plastics Plastics Group A
& Tires Plastics
ESFR 5,000 2,500 5,000 1,000 2,500

(K=14) (465) (232.5) (465) (139.5) (232.5)
ESFR 5,000 Not 5,000 Not Not Allowed

(K=25) (465) Allowed (465) Allowed
K-17 5,000 2,500 5,000 Not 2,500

(465) (232.5) (465) Allowed (232.5)
All sprinklers in this category must be strictly installed in accordance with their
Listing/Approval and in accordance with current NFPA standards (e.g., building height,
storage height, clearance). No deviations allowed.
Note: Pile sizes in areas protected with specific application sprinklers not listed
above are subject to review by Global Security.
Table 3.6.3-a Fire Protection for Small Warehouse Facilities Based on Facility Size,
Inventory Values, Lease Agreements and Business Continuity
Fire Protection Table

Table Table Table
Decision Factor 3.0-c 3.6.3-b 3.6.3-c
100,000-500,000 ft2 (9290-46,452 m2) X

Facility Size 75,000-100,000 ft2 (6968-9290 m2) X
Less than 75,000 ft2 (6968 m2) X
Inventory/Equipment $10 M USD or Greater X

Values Less than $10 M USD X
Greater than 3 years X

Lease Agreement
3 years or less X
Maximum interruption > five days X

Business Continuity
Maximum interruption < five days X
Shipping Criteria 10,000 or greater X

(Lines per day) Less than 10,000 X
Table 3.6.3-b Minimum Requirements for Small Warehouse Facilities
<75,000 FT2 (6968 M2)
Category Requirement
- Due diligence: Worldwide Real Estate, Global Security

Facility Selection
and Risk Management
- Follow local codes regarding sprinklers, smoke detection,

fire hose, portable extinguishers and egress components
Fire Protection
- Establish and enforce appropriate smoking regulations.
- Maximum pile sizes of 2,500 ft2 (232 m2)
- Aisle between piles must be twice as wide as pile is high

Housekeeping
- No combustible storage against exterior of building
- Remove rubbish daily
- Establish business continuity plans for business

Business Continuity
interruptions of greater than 5 days
Table 3.6.3-c Warehouse Fire Protection 100,001 ft2 (9,290 m2) - 500,000 ft2 (46,452 m2)

CATEGORY
sprinkler/hose stream demand exposure warrants)
One fire pump 2,500 GPM Fire Pump (9464 L/min) Public supply may be acceptable
WATER alternative
SUPPLIES
Duration of water supply 120 minutes (250,000 gal tank) Each source
(946000 l)
Water distribution Looped fire main of ductile iron, 12” 10” (250 mm) PVC Class 200 FM approved
(300mm) minimum diameter may be acceptable alternative
Hydrants NFPA 24 500 ft. (152 m) spacing
2 2
Office occupancies 0.1 gpm/ft (4.1 L/min/m ) over most Head spacing may be extended to 225ft2
remote 3000ft2 (280 m2) – 130ft2 (12 (21 m2) if wall between warehouse and
2
m ) maximum head spacing office has minimum 2 hr fire rating
Computer Room 0.12 gpm/ft2 (4.9 L/min/m2) over most Same maximum head spacing as office
2 2
AUTOMATIC remote 3000ft (280 m ) occupancies
SPRINKLERS
Warehousing, rack and bulk Design to supply 12 K-25 ESFR As an alternative, K-17 heads may be used
sprinklers operating at minimum end at a density of .8 gpm/ft2 (32.6 L/min/m2)
2 2
head pressure of 20 psi (1.4 bar) over 2,000 ft (186 m )
2 2
(or as required per the listing) 90 ft (8.4 m ) head spacing
If obstructions cannot be avoided,
design to 14 heads at 20 psi (1.4 bar)
2
80-100ft head spacing
Below walkway/mezzanine 0.4 gpm/ft2 (16.3 L/min/m2) over Feed from adjacent ceiling system
2 2
2,500 ft (232 m )
Inside hose connections NFPA 13 as appropriate Sufficient number and spacing for two point
attack. Feed from adjacent ceiling system
Alarm system NFPA 72 & GMFP&P, Chapter 5 Approved/listed central station or

proprietary
BUILDING
FEATURES Fire extinguishers NFPA 10 Spacing as appropriate
Venting Manual mechanical exhaust at Throughout warehouse area

minimum rate of 1.5 cfm/ft2 of floor
3 2
area(0.042 m /m )
Firewalls, partitions Minimum 1 hour fire rated masonry Fire rated glass in windows, or line of
wall between warehouse and office sprinklers above
Yard Storage GMFP&P Chapter 3 Deviation-Global Security
Roof GMFP&P Chapter 4 UL or FM requirements

Protection of Special Hazards
Level
1.0 PURPOSE
This standard provides the overall facility requirements of General Motors

locations as related to the special hazards identified herein.
2.0 SCOPE

regulations may supersede the GM standards
3.0 STANDARDS
3.1 Computer Rooms
This section provides guidelines on the construction and fire protection of main
computer rooms and remote data processing operations.
Prohibit smoking in computer rooms, data storage rooms, supplies storage

rooms and support areas.
3.1.1 Construction
Separate computer rooms from adjacent areas by a minimum one hour fire rated
barrier extending from the structural floor to the structural ceiling. Separate the
media storage area by a two hour fire rated barrier.
All finishing materials for the computer room including walls, floors, partitions,
acoustical treatment, raised floors, raised floor supports, suspended ceilings and
others, must have a flame spread rating of 25 or less.
3.1.2 Fire Protection
Provide automatic sprinkler protection throughout the computer room, data

storage room, supplies storage room and any associated support areas. Design
sprinklers to provide a minimum density of 0.10 gpm/ft2 (4.0 L/min/m2) over any
and the most remote 3,000 ft2 (280 m2) area of application. Ordinary wet-pipe
sprinklers are preferred in the computer room. A pre-action system is an
acceptable alternative. Provide a separate valve control for the computer room
sprinklers.
1
Level
In data storage rooms where there are concentrations of exposed plastic

materials, such as tapes or disks in plastic cases on open shelves, provide a
minimum sprinkler design density of 0.28 gpm/ft2 (11.4L/min/m2) over any and the
most remote 3,000 ft2 (280 m2) area of application.
Provide a smoke detection system, connected by supervised circuitry to the

facility’s alarm system, throughout the computer and data storage rooms,
including subfloors. Provide cross-zone wiring arrangements for pre-action
sprinkler system or gaseous extinguishing system release.
Use only listed plenum rated cable in the subfloor, or fully house all cables in
conduit.
Prohibit electrical devices not related to data processing operations, such as

coffee pots and electrical heating devices.
Restrict paper stock and other combustibles to the minimum necessary for
efficient operations. Store this material in enclosed metal cases or cabinets, or
restrict these combustibles to the supplies storage area.
3.2 Engine Test Operations
This standard contains minimum requirements for new and renovated

installations for General Motors facilities worldwide (including non-General
Motors operations conducted on General Motors property). These requirements
must be followed except where more stringent governmental regulations apply.
Upgrade existing engine testing installations that do not conform to the

requirements of this Chapter where the discrepancies are recognized hazards to
life or property, or they conflict with enforceable governmental regulations.
3.2.1 Engine Hot Test Areas, Chassis Dynamometer Areas and Fuel Flow
Operations
3.2.1.1 Construction
Isolate engine hot test areas from other occupancies, including control rooms, by
a one hour rated fire barrier, or at a minimum, a deep draft curtain as defined in
Chapter 4, Section 3.3.1.3 of this manual.
2
Level
Isolate chassis dynamometer areas from other occupancies by a minimum one

hour rated fire barrier. Special chassis dynamometer areas, such as those that
simulate extreme environmental conditions, are subject to an engineering review.
Isolate fuel flow operations from other occupancies by a minimum one hour rated
fire barrier.
Materials used in construction must be resistant to accumulation of flammable

and combustible materials which may provide a "wick" effect.
Avoid the use of pits, trenches or basements where possible. If pits or basements
are required, provide appropriate exits from at least two points. All operations
necessary for employee entrance into pits or basements must be in accordance
with Local or Facility Confined Space Entry Procedures.
Provide floor drains wherever fuel spillage is possible in test rooms in which
liquid fuel is used.
Provide at least two means of egress from 1) any test enclosure where fuel is
used and 2) in all enclosures adjoining a hazardous area in order to minimize the
possible entrapment of personnel.
3.2.1.2 Fuel Systems
See 3.3 for fuel farm unloading and storage.
Piping
Locate fuel supply and return lines outside of buildings.
Maintain the fuel system at the lowest pressure at which the system will operate.
Pitch fuel distribution piping to drain to the outside, with a valved connection to a
receiving tank.
Clearly identify all piping used in the transfer of hazardous flammable materials in
accordance with applicable local regulations.
Pressure test all fuel piping systems in accordance with ANSI B 31.3 or an
equivalent standard.
3
Level
Valves must provide positive shutoff in the event of exposure to fire.
Use valves with position indicators.
Protect fuel lines from mechanical damage.
Sleeve all fuel lines passing through walls or foundations. Pack sleeves with
non-hardening caulking compound.
Provide for expansion and/or contraction of fuel lines.
Securely fasten piping to prevent vibration and sagging.
Ensure natural gas piping complies with applicable local standards.
Flexible piping must be approved by a recognized testing laboratory for the fuel
used.
Fuel Delivery
Design fuel delivery equipment for above-ground tanks to prevent siphoning of

liquid fuel from the tanks.
Limit inside compressed natural gas storage to six 1.5 ft3 (42.5 L) cylinders,
arranged in a manifold, with no more than one bottle in use at any one time.
Fuel Measurement Systems
Ensure fuel measurement devices are electrically classified or rated intrinsically

safe as to location.
Locate the fuel measurement system in the test cell or in a room specifically
designed for handling fuel. Arrange the equipment to prevent physical damage
from other equipment.
Provide mechanical ventilation within enclosures housing fuel measurement

equipment sufficient to prevent the accumulation of explosive mixtures.
Terminate measurement system fuel vapor vents at a floor drain.
4
Level
Design and install fuel cooling and conditioning equipment to prevent fuel from
mixing with any other substance.
Pumps and Pump Rooms
Provide a one hour fire rated enclosure for the pumps when located within the
building.
Provide a relief valve for any positive displacement pump.
Ensure pump motors are electrically classified as to location.
Ground pumps and pump motors independent of piping.
3.2.1.3 Ventilation
Provide continuous (up-time and down-time) mechanical ventilation in enclosed

areas, including basements and pits.
Provide indirect heat only, where heat is required.
Provide a minimum ventilation rate of one cfm per ft2 (28.3 L per 0.09 m2) of floor
area, exclusive of recirculated air.
Locate room exhaust pickups at a maximum of six inches (15.2 cm) above floor
level.
Provide interlocks to automatically terminate testing and shut off appropriate fuel
systems upon loss of ventilation.
Equip the following with an exhaust system mechanically vented to the outdoor
atmosphere:
Engine hot test stands
Engine hot test stations
Chassis exhaust systems
5
Level
Chassis exhaust sampling systems
Provide continuous mechanical exhaust in any trench space, adequate to

prevent the accumulation of explosive mixtures of fuel, vapor and air.
3.2.1.4 Electrical
Electrical equipment and wiring must conform to Article 500 and other applicable
provisions of NFPA 70, or an equivalent standard.
Install equipment and wiring in accordance with General Motors Standards El-1
Electrical Installation Standard for Buildings and Facilities and ES-1 Electrical
Standard for Industrial Equipment.
Provide electrical equipment rated as Class I, Group D, Division 1 or Zone 1 for

hazardous locations as defined in Article 500 of NFPA 70, or equivalent, within
pits, basements and trenches.
Ensure all electrical equipment located within 18 inches (0.5 m) of grade level is:
rated as Class I, Group D, Division 2 or Zone 2; or rated as non-classified in
accordance with Article 501 of NFPA 70, or equivalent.
Do not locate Test Area power supplies, including batteries or terminals for
engines, in close proximity to fuel supply couplings.
3.2.1.5 Hazard Control Equipment
Provide vapor detection arranged to sound an alarm at 20 percent of the lower

flammable limit. Ensure the alarm sounds at a constantly attended location.
Provide interlocks to automatically shut off all process equipment, except

ventilation, upon detection of 40 percent of the lower flammable limit.
Provide a wet pipe sprinkler system throughout the facilities, including exhaust
hoods, hydraulically designed to deliver a density of 0.30 gpm per ft2 (12
L/min/m2) over any and including the most remote 3,000 ft2 (280 m2) area of
application. Protect duct systems with sprinklers controlled by a readily
accessible valve.
6
Level
Protect each test stand or group of test stands in engine hot test operations or
fuel flow rooms with one of the following, activated by heat detection:
An approved two-shot local application fixed gaseous extinguishing

system
An approved watermist extinguishing system
Protect control rooms utilized to monitor test operations with automatic sprinklers
installed in accordance with applicable sections of this manual.
Install fixed gaseous extinguishing system detection in accordance with the

applicable provisions of NFPA 72 – National Fire Alarm Code, or equivalent
standard. Arrange these detection systems to:
Sound alarms locally and at the plant proprietary alarm console
Shut off fuel supply to the area
Shut off electrical power, engine ignition, air systems, ventilation fans,
dampers, cranes and hoists
Activate the fire extinguishing system
Provide fire extinguishers throughout the facility.
Prohibit smoking or use of open flames in areas where flammable or combustible

liquids or flammable vapors are present.
Provide grounding and bonding of fuel handling and/or fuel piping systems.
3.2.2 Engine Test Cells and Environmental Test Cells
3.2.2.1 Location and Construction
Locate test cells adjacent to an outside wall in a one story building with no
unrelated facilities or normally occupied spaces above or below.
Provide explosion relief venting for each cell. As a minimum, use the entire
outside wall for explosion relief.
7
Level
Isolate test cells from other occupancies, including control rooms and adjacent
test cells, by walls having a fire resistance rating of two hours and blast
resistance rating of 100 pounds per ft2 (4.8 kpa). Prohibit the installation of
viewing windows that reduce these ratings.
3.2.2.2 Fuel Systems
Follow 3.2.1.2 in addition to the following:
Do not locate or store compressed natural gas within test cells.
Do not pour fuel from one container to another inside of an environmental

test cell, regardless of the ambient temperature.
3.2.2.3 Ventilation
All requirements of 3.2.1.3 apply.
3.2.2.4 Electrical
All requirements of 3.2.1.4 apply.
3.2.2.5 Hazard Control Equipment
Apply 3.2.1.5 with the following exceptions:
Provide a wet pipe sprinkler system throughout the facilities, including

cells, hydraulically designed to deliver a density of 0.60 gpm per ft2 (24.4
L/min/m2) over the entire floor area. Protect duct systems with sprinklers
controlled by a readily accessible valve.
Locate vapor detection at the floor when vapors from fuel are heavier than
air.
Locate vapor detection at the ceiling when vapors from fuel are lighter
than air.
3.2.3 Handling of Fuels at Elevated Temperatures
3.2.3.1 Location of Heating Equipment
8
Level
Locate heaters as close as possible to the engine or test fixture, within the test
cell, or in a room specifically designed for handling fuel.
Locate fuel conditioning equipment in an area with complete hazard control

equipment as specified in this document, and arrange it in such a manner as to
prevent physical damage.
Do not heat fuel in pits, trenches or basements.
3.2.3.2 Equipment
Use equipment, including seals, gaskets and all materials of construction that is
rated above the maximum operating temperature. All wetted materials must be
compatible with the specific fuel being used.
Meet or exceed the requirements of the previous sections for all piping and
electrical equipment.
Provide appropriate monitoring and control for high temperature and high/low
pressure and level limits.
3.2.3.3 Methods of Heating Fuel
Steam to Water/Water to Fuel
Provide methods to ensure that the media do not mix. Stainless steel heat
exchangers and conditioned water are recommended to reduce component
failure. Provide steam at the lowest possible pressure required to perform the
test.
Steam to Fuel
Provide methods to ensure that the media do not mix. Provide steam at the
lowest possible pressure required to perform the test.
Electric Heater to Oil/Oil to Fuel
Use electric heaters with caution, and only if the following conditions are met:
9
Level
Ensure the heater and installation meet the requirements of the General
Motors Standards ES-1, EI-1 and all electrical requirements set forth in
this document.
Ensure the heater, when continuously energized with 110 percent rated
voltage, does not have an internal or external temperature exceeding the
ignition temperature of the fuel and/or oil being used. Ensure oils meet the
operating and safety requirements of the fuel conditioning equipment and
the test specifications.
Direct Electric Heating
Use direct electric heaters only if the following conditions are met:
Ensure the heater meets or exceeds the requirements of the General

Motors Standards ES-1, EI-1 and all electrical requirements set forth in
this document.
Ensure electrical safety devices are sized to reflect the actual operating
currents to protect equipment, buildings and personnel.
Ensure the heater, when continuously energized with 110 percent of the
rated voltage does not have an internal or external temperature exceeding
the ignition temperature of the fuel being used.
3.2.4 Compressed Gas Bottle Storage and Use
3.2.4.1 Location and Construction
Locate compressed gas bottle storage in a separate room with at least 25

percent of the perimeter being an exterior wall.
Provide explosion relief venting for the compressed gas bottle storage room.
Isolate bottle rooms from other occupancies with walls of a minimum of one hour
fire resistance rating.
3.2.4.2 Distribution Piping
10
Level
Ensure the distribution system operating pressure is at the minimum required

operating pressure.
Ensure the distribution system design pressure exceeds the maximum container
storage pressure.
Provide manual service shut-off valves and lock-out provisions at the user
locations.
Provide properly sized flow limiters on each distribution line, as close as possible
to the gas source.
3.2.4.3 Ventilation
Provide continuous mechanical exhaust ventilation at a rate of 15 volume

changes per hour for the room and storage cabinets.
Provide 100 percent outside air supply.
Monitor ventilation for failure with alarms that sound locally and at a constantly
attended location.
Limit room temperature to 125 degrees Fahrenheit (52o C)
Maintain the storage room at negative pressure to the surrounding occupancies.
Locate room exhaust ducts no more than 6 inches (15.2 cm) from the floor level,
and at ceiling level to eliminate the pocketing of harmful vapors.
3.2.4.4 Electrical
Ensure electrical equipment is properly classified for hazardous locations and

complies with General Motors Standards El-1, ES-1 and all electrical
requirements set forth in this document.
3.2.4.5 Hazard Control
Provide vapor detection arranged to sound an alarm at 20 percent of the lower

explosive limit. Ensure the alarm sounds at a constantly attended location.
11
Level
Provide interlocks to shut off all equipment, with the exception of ventilation,
upon detection of a vapor concentration of 40 percent of the lower explosive limit.
Provide a wet pipe sprinkler system throughout the facilities, including exhaust
hoods and storage cabinets, hydraulically designed to deliver a density of 0.30
gpm per ft2 (12 L/min/m2) over any including the most remote 3,000 ft2 (280 m2)
area of application. Protect duct systems with open-head sprinklers controlled by
a readily accessible valve.
3.2.5 Operations
Do not store or use unrelated combustible materials within the storage room.
Conduct leak tests at least annually to ensure the integrity of the entire supply
piping system.
Provide Emergency Stop stations within each fire area in case of failure or
damage to the supply piping.
Do not exceed 200 ft (66 m) of travel distance to the nearest station.
Arrange the system to sound an alarm locally and at the facility proprietary
alarm console in the event of Emergency Stop operation.
Provide identification labeling of the storage room and distribution piping.
Secure all bottles by chain and/or straps to prevent falling.
3.3 Outside Storage of Fuels
This standard applies to the outside storage of liquefied petroleum gas (LPG),
flammable and combustible liquids and associated equipment.
Table 3.3.a summarizes the location/spacing and protection requirements for

above ground tanks containing flammable or combustible liquids.
table 3.3.a.doc
12
Level
Table 3.3.b summarizes the location/spacing and protection requirements for

LPG tanks, vaporizers and unloading stations.
table 3.3.b.docx
3.3.1 Fuel Unloading Stations
Locate unprotected fuel unloading stations at least 100 ft. (33 m) from the
nearest buildings or at a distance prescribed by applicable codes or regulations,
whichever is greater.
EXCEPTION: Locate compressed natural gas unloading stations a minimum

of ten ft. (3.3 m) from the nearest building.
Provide protection for fuel unloading stations located within 100 ft. (33 m) of any
building.
EXCEPTION: Compressed natural gas unloading and storage facilities do not

require fixed fire protection.
Fuel transfer operations must be attended.
3.3.2 Storage Tanks
Locate and/or protect above ground storage tanks per Table 3.3.a.
Label fill pipes and underground storage tanks to indicate contents.
Properly identify the capacity of all aboveground and underground tanks.
Provide level indication to show amount of contents in tank.
Equip tanks with low-resistance, high-capacity grounding.
Employ tanks, gauges and fittings approved by a recognized testing laboratory.
13
Level
Provide tanks with adequate alarms to avoid overflow condition.
Surround tank vents, filler pipes and pumps with dikes of sufficient capacity to
contain any overflow.
3.4 Fluid Fill Operations
This standard applies to all new and existing fluid fill operations.
In addition to the following information, please refer to details contained in

General Motors Mechanical Design Common Systems MDG-13, Fluid Fill
Operations.
3.4.1 Class I & II Fluids Delivery Piping
Use minimum Schedule 40 welded carbon steel pipe for fuels and 100%
windshield washer solvent.
Use minimum Schedule 40, 304 stainless steel pipe for water/windshield washer
solvent mixtures.
Components used in the processing, transferring, or dispensing of fluids, must be

chemically compatible with the fluid in use.
Use either double pass socket welded, gasketed flange with 150 PSI (10.34 bar)
welded type flanges or mechanically attached fittings for all piping connections.
Mechanically Attached Fittings (MAF) must not rely on O-rings, elastomeric, or
rubber seals to provide a leak-free joint. MAF must be permanent compression
style fittings which cannot be disassembled and reused. Avoid threaded piping
due to increased leakage potential.
3.4.2 Fluid Fill Area
3.4.2.1 Ignition Source and Spill Control
If the floor grating or plating in the dispensing area is to be covered with matting,
use only conductive materials. If located over grating, use only matting with
openings representing at least 40% of the surface area.
14
Level
Provide a fuel/water separator for the recovery of flammable fluids for all pit
installations that have an automatic water wash system.
Provide spill containment and/or a special drainage system for dispensing areas
without pits. Provide spill containment drainage that will allow the fluid to flow to
a common collection point. Provide an accessible collection point for clean-up,
recovery, or maintenance by qualified personnel.
Prohibit smoking in the fluid fill area.
3.4.2.2 Fluid Fill Area Piping and Tubing
Ensure all piping which is used for processing, transferring, or dispensing of

fluids, meets the criteria established in 3.4.1.
Ensure tubing used for processing, transferring, or dispensing of fluids meets the
following requirements:
Use carbon steel tubing for fuels and 100% windshield washer solvent.
Use minimum 304 stainless steel tubing for windshield washer solvent
mixtures.
Determine tubing wall thickness for each diameter based on 3000 psi
working pressure after de-rating factors are applied.
Ensure all tubing connections meet the same conditions as piping specifications
as per 3.4.1.
3.4.2.3 Electrical Equipment
Use only Class I, Group D, Division 1 or 2 (Zone 1 or 2) electrical equipment in

the fluid fill area.
Properly bond and ground all dispensing and processing equipment.
Install a noncombustible vapor barrier along the traffic aisles on either side of the
classified area to limit the extent of the electrical classification boundary for
above grade areas. The installation of this barrier will eliminate the need for
rated electrical equipment in the aisle. Extend the barrier 25 feet (7.62 m)
15
Level
beyond the fluid dispensing area.. Install self-sealing exit doors in the barrier
walls as required.
3.4.2.4 Ventilation
Provide continuous mechanical low-level ventilation at a minimum rate of 1

cfm/ft2 (0.3 m3/min/m2) for the dispensing and metering areas plus 10 ft (3.0m)
beyond the dispensing area.
Note: It may be required to specify a higher ventilation rate due to threshold

limit values.
Equip each exhaust ventilation fan with a dedicated differential airflow switch.
Prove airflow before the dispensing equipment can be activated and other
interlocks enabled.
Separate adjacent pit areas and trenches by a masonry or sheet steel

constructed barrier up to any openings required for operation.
3.4.3 Fire Protection and Prevention
Automatic Sprinklers
Provide automatic sprinkler protection over, and for 20 ft (6.1 m) beyond, the
classified fuel dispensing area on a designed density of 0.60 gpm/ft2 (24.5
lpm/m2). Include protection under any overhead obstructions such as ductwork,
mezzanines, stairways, piping assemblies, etc.
Provide automatic sprinkler protection, hydraulically calculated to deliver a

density of 0.30 gpm/ft2 (12.2 lpm/m2) for the entire area, for all pits and trenches
that meet either of the following conditions:
Pits greater than 3 ft. (.91 m) deep
Where drip pans are provided in pits or trenches and the area beneath the
pans are part of the exhaust system
3.4.3.1 Windshield Washer Fluid System
Provide any pit areas deeper than 3 ft. (.91m) with automatic sprinkler protection.
16
Level
Maintain all pits free of combustible debris.
Maintain the floor around the windshield washer test area free of accumulations
of the windshield washer fluid.
Designate the area as a “Non-Smoking” area.
Provide flammable gas detectors in adjacent pit areas where the potential for
vapor accumulation exists.
3.4.3.2 Emergency Manual Pull Stations
Install manual emergency stop buttons located at the dispensing station.
3.4.3.4 Interlocks & Proprietary Signaling
Refer to Table 3.4.3.4 for required fluid fill process and alarm interlocks.
table 3.4.3.4.xls
The fire alarm control panel must be placed outside the classified area, visible to
operators, and easily accessible.
3.4.3.5 Operations
To minimize sources of ignition, do not start the vehicles within the vapor barrier.
Do not connect the battery or conduct other electrical tests within the vapor
barrier.
Clearly label the dispensing area and floor as "No Smoking" and "Restricted
Ignition Source".
After fueling, install fuel filler cap within the fluid fill area.
3.4.3.6 Process Equipment Requirements
17
Level
Arrange all automatic and manual dispensing equipment to automatically shut off
after the delivery of the preset quantity of fluid.
Chill fuel (if required) through an indirect method such as shell and tube or
brazed plate heat exchangers.
3.4.4 Fire Protection and Interlock Testing
Perform a field acceptance test, per a site-specific test matrix, for new
installations and major renovations. Complete acceptance testing prior to
introduction of fluids.
Properly trained personnel must perform annual fire protection systems and
interlock testing per a site-specific test matrix.
3.5 Oil Mist Exhaust Ductwork and Collectors
Description: Protection requirements for exhaust air ductwork and collectors are
based on type of coolant used in the operation, physical dimensions, and
accumulation and combustibility of residues.
3.5.1 Operations Using Water Soluble Coolant
Ensure at least one of the following conditions is met for all ductwork having a
cross sectional area greater than 100 in.2 (0.0645 m2):
Provide sprinkler protection
Implement a housekeeping/cleaning schedule at sufficient intervals to

prevent excessive residue accumulation within the duct.
Provide access doors in all ductwork at minimum 50 ft (15.2 m) intervals to allow

inspection for residue accumulation and to facilitate cleaning. Additional access
doors may be needed for access to sprinkler heads.
If the residue is combustible, provide sprinkler protection for the collectors and/or
filters.
3.5.2 Operations Using Mineral Oil Coolant
18
Level
Provide sprinkler protection in all ductwork having a cross sectional area greater
than 100 in.2 (0.0645 m2).
Provide access doors in all ductwork at minimum 50 ft (15.2 m) intervals to allow

inspection for residue accumulation and facilitate cleaning. Additional access
doors may be needed for access to sprinkler heads.
If the residue is combustible, provide sprinkler protection for collectors and/or

filters.
Provide an emergency manual shut-down device, interlocked with the ventilation

system, at an accessible and properly labeled location near the machining
operation.
3.6 Material Storage
3.6.1 Miscellaneous Indoor Storage
This section refers to miscellaneous storage associated with production

operations. The provisions of Chapter Two, Section 3.6.3.3, Warehousing –
Storage Arrangement and Fixed Protection Requirements, apply to the storage
types, heights, aisles, and protection features for miscellaneous storage.
3.6.2 Yard Storage
Locate combustible yard storage at least 100 ft {30.5m} from all important
buildings, pipe racks, flammable liquids storage areas and electrical substations.
Maintain non-combustible yard storage a minimum of 50 ft. {15m} from the
buildings for manual firefighting access.
Limit pile sizes to 2,500 ft2 {232.5m2}. Long, narrow storage piles are preferred
to square blocks.
Maintain aisles between piles twice as wide as the pile height.
3.7 Operations Involving Hydrogen Fuels
The following sections outline basic requirements for fire prevention and
protection when using hydrogen as a fuel for vehicles. Due to the many
variables that could affect the requirements, an engineering review is required
19
Level
when undertaking operations in new or existing buildings. Refer to flowchart 3.7

to aid in the decision-making process regarding operations involving hydrogen
fuels and any associated facilities not specifically addressed herein.
Flow Chart 3.7
3.7.1 General Conditions
3.7.1.1 Room Ventilation
Arrange room ventilation to maintain the vapor concentration below 25% of the
Lower Flammable Limit (LFL). Base calculations on the largest probable release
aside from a full tank rupture.
For fixed piping hydrogen delivery systems into a room, interlock the ventilation
with the hydrogen gas valve so the valve will not open if the ventilation is not
operating.
The following are required for rooms using both hydrocarbons and hydrogen:
Provide both upper and lower ventilation pick-ups.

Ensure both upper and lower ventilation rates are met.
Conduct an engineering review to verify that proper airflow is provided

throughout the space for new construction, or for buildings or rooms that are
being modified to conduct tests on hydrogen fueled systems. Conduct a smoke
test to verify that there are no dead air spaces within the building or room.
3.7.1.2 Electrical
Use electrical equipment that is appropriately classified for hazardous locations

and conforms to the applicable provisions of General Motors Standards EI-1 and
ES-1. Equipment must meet at least one of the following:
Minimum Class I, Division 2 (Zone 2), Group B
Intrinsically safe
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Level
Purged and ventilated
Where hydrocarbon fuels (gasoline, methanol, etc) are used in addition to

hydrogen, also apply the electrical requirements as outlined in 3.2.1.4.
Provide emergency lighting.
Provide proper bonding and grounding.
3.7.1.3 Protection
Provide vapor detection arranged to sound an alarm at 20 percent of the LFL.

Ensure the alarm sounds at a constantly attended location. Locate sensors at the
ceiling.
Interlock all process equipment, including the fuel supply, to automatically shut
off In the event the vapor concentration reaches 40 percent of the LFL. Ensure
exhaust ventilation remains on at all times.
Provide an audible alarm and a strobe mounted on the outside of each entrance
to the test cell and in the control room. The alarm and strobe must be activated
upon 20% LFL detection. Ensure the audible alarm is distinguishable from the
“Employee Evacuation” notification and sounds at the security proprietary control
console.
Provide clearly marked emergency manual shut off valves for fuel lines.
Do not permit smoking or the use of open flame in areas where flammable gas
vapors may be present.
3.7.1.4 Location of Gaseous or Liquid Hydrogen Systems
Locate Gaseous and Liquid Hydrogen Systems in accordance with NFPA 55 or

applicable local codes or regulations.
3.7.2 Test Cell Operations
Test cell operations include any small rooms such as engine or vehicle
dynamometer cells, noise and vibrations rooms, etc. where normally only one
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vehicle would be undergoing tests. Due to the many variables that could affect
fire protection requirements, an engineering review is required. The
requirements below present the most restrictive approach based on large
volumes of hydrogen gas usage or release potential.
3.7.2.1 Location
Locate the test chamber(s) in which hydrogen fuel will be used adjacent to an
outside wall in a one-story building with no unrelated facilities or normally
occupied spaces installed above or below.
Isolate test chamber(s) from other occupancies, including control rooms and
adjacent test cells, by walls and ceiling having a fire resistance rating of two
hours and minimum blast resistance rating of 100 pounds per ft2 (4.8 kPa).
Construct exterior walls of lightweight materials or panels designed to relieve at a
maximum internal pressure of 20 lb/ft2 (13.3 kPa/m2).
Install explosion relief venting in accordance with NFPA 68 or equivalent local

standards. As a minimum, the entire outside wall must be the means to obtain
relief.
Do not install viewing windows without prior approval from Global Security. If
approved, install viewing windows having explosion and/or impact resistance
commensurate with the test cell wall construction.
Provide appropriate exits from at least two points of basements or pits. Ensure
employee entrance into basements is in accordance with local or facility confined
space entry procedures.
3.7.2.3 Room Ventilation
Refer to 3.7.1.1 General Conditions - Ventilation
3.7.2.4 Electrical
Refer to 3.7.1.2 General Conditions - Electrical
3.7.2.5 Protection
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Provide a wet pipe automatic sprinkler system capable of providing a density of

0.30 gpm/ ft2 (12.2 L/min/m2) over the lesser of 3,000 ft2 (280 m2) or the entire
area of application.
Design automatic sprinkler protection in the control rooms to provide a density of

0.10 gpm/ft2 (5 L/min/m2) over the lesser of 3000 ft2 (280 m2) or the entire area.
If a raised floor is provided in the control room, follow the requirements of 3.1.
See also 3.7.1.3 General Conditions - Protection
3.7.2.6 Special Considerations
Locate the hydrogen fuel source outside the test cell, and pipe the gas to the test
cell for use as needed.
Provide a valve (powered open, fail closed) on the hydrogen fuel source.
Interlock the valve to the hydrogen detection in the test cell such that a detected
level of 20% LFL will shut off the fuel supply.
3.7.3 Lab Hood Operations
Apply this section to the use of hydrogen in laboratories. This is defined as a

facility where the “laboratory use of hazardous chemicals” occurs. It is a
workplace where relatively small quantities of hazardous chemicals are used on
a non-production basis.
Isolate lab hood operations from adjacent test operations by walls having a
minimum fire resistance rating of one hour.
Install viewing windows, if required, commensurate with test operation wall

construction.
Provide a secondary means of egress from a lab hood operations work area if
any of the following apply:
The area exceeds 500 ft2 (46 m2)
A lab hood is located adjacent to the primary means of exit access
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A compressed gas cylinder is in use and is larger than a lecture bottle

(approximately 2 in. (5 cm) by 13 in. (33 cm) ).
An accidental release of the cylinder contents prevents safe egress.
Provide emergency lighting for any lab hood operation areas requiring a
secondary means of access to an exit.
Ensure all hoods are of non-combustible construction.
3.7.3.2 Ventilation
Design ventilation to ensure that chemical vapors which originate from within the
laboratory hood systems are not re-circulated. Control the release of chemicals
into the laboratory through the use of enclosures or a method of capture to
prevent hydrogen or other flammable and/or combustible concentrations of
vapors from reaching any source of ignition.
Ensure laboratory hood face velocities and exhaust volumes are sufficient to
contain contaminants generated within the hood and exhaust them outside of the
laboratory building. Ensure the hood provides containment of the possible
hazards (or exhausts to the outdoors as in the case of hydrogen) and protection
for personnel at all times when chemicals are present in the hood.
Construct ducts from laboratory hoods entirely of noncombustible materials.

Ensure fans and other electrical portions of the exhaust systems meet the
requirements of 3.7.3.3.
Discharge air exhausted from the laboratory hoods above the roof at a location,
height and velocity sufficient to prevent re-entry of chemicals into the building
through ventilation air intakes.
Ensure ventilation systems comply with NFPA 45 or local equivalent.
In laboratories where single (or multiple) cylinders of hydrogen are used, ensure
the cylinders are kept in a cabinet and the cabinet has mechanical ventilation to
the outside. Provide sprinklers within the cabinet.
3.7.3.3 Electrical
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Ordinary (non-classified) electrical equipment may be used in rooms where Lab

Hood Operations are performed, with the following exceptions:
Provide Class I, Division 2 (Zone 2), Group B electrical equipment at the

ceiling level to 18 inches below the ceiling in areas where hydrogen is
handled outside of a lab hood.
Provide Class I, Division 2 (Zone 2), Group D electrical equipment at the

floor level to 18 inches above the floor where gasoline or other flammable
liquids are handled outside of a lab hood.
Provide Class I, Division 2 (Zone 2), Group B electrical equipment inside lab
hoods due to the potential for hydrogen vapors.
Where receptacles are located inside a lab hood, locate additional accessible
and clearly marked electrical disconnects within 50 ft (15m).
Locate controls for lab hood services (e.g. gas, air and water) external to the
hood.
3.7.3.4 Protection
Provide rooms containing Lab Hood Operations with a wet pipe automatic
sprinkler system capable of providing a density of 0.30 gpm/ ft2 (12.2 L/min/m2)
over the lesser of 3,000 ft2 (280 m2) or the entire area of application.
Provide vapor detection arranged to sound an alarm at 20 percent of the LFL.

Ensure the alarm sounds at a constantly attended location. Locate sensors at the
floor and/or ceiling depending on fuel characteristics.
Ensure the following occurs in the event the vapor concentration increases to 40
percent of the LFL:
Automatically shut off all process equipment and fuel supply.
Activate high-level ventilation for the area.
The high level vapor alarm sounds at the security proprietary alarm
console.
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3.7.4 Fuel System Operations within General Buildings and Garages
General
Do not fuel vehicles indoors.
Prohibit the placement of the vehicle in a non-ambient area such as a paint booth
oven, climatic chamber, etc., without prior engineering review.
Do not involve the vehicle in crash testing without prior engineering review.
3.7.4.1 Location
Locate any area housing hydrogen fueled vehicles on which fuel system work will
be performed, adjacent to an outside wall in a one-story building with no
unrelated facilities or normally occupied spaces installed above or below.
Designate specific vehicle stalls for hydrogen fuel system operations, and
prohibit fuel system work outside these areas.
Isolate the garage operations from other occupancies by walls having a minimum
fire resistance rating of two hours.
Provide at least two means of egress from any garage.
3.7.4.3 Ventilation
Ensure the air handling system is capable of 6 air changes per hour in open
garage areas.
Place a hood over the stall(s) designated for fuel system work. Vent the hood
directly to the outdoors using mechanical ventilation capable of at least 1 cfm per
ft2 (28.32 L per 0.09 m2) of hood area.
3.7.4.4 Electrical
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Ensure electrical equipment located within 18 inches of the ceiling is classified a

minimum Class I Division 2 (Zone 2).
Ensure any electrical equipment within the hood over the fuel system work area,
and 18 inches below the hood, is classified a minimum Class I Division 2 (Zone
2).
3.7.4.5 Protection

0.30 gpm/ft2 (12.2 L/min/m2) over the lesser of 3,000 ft2 (280 m2) or the entire
area of application
Install automatic sprinklers under the hood, over the fuel system work area.
Install hydrogen detection in the hood, arranged to sound an alarm when 20% of
the LFL is detected. Also ensure the hood ventilation is engaged, regardless of
its previous on/off position.
If the other portions of the building will be used for hydrogen vehicle storage or
non fuel system work, refer to the requirements of 3.7.5.
3.7.5 General Buildings, Including Garages, Without Fuel System Work
An engineering review is required prior to any deviation from the requirements of

this Section.
The following are general requirements for hydrogen fueled vehicles inside
buildings:
Prohibit hydrogen fueled vehicles inside general building areas unless

equipped with an onboard hydrogen detection system that can isolate the
fuel source in the event of a leak.
Prohibit vehicles equipped with auxiliary fuel tanks. Only permanently

affixed tanks, engineered with the vehicle are acceptable.
Prohibit the placement of the vehicle in a non-ambient area such as a

paint booth oven, climatic chamber, etc., without prior engineering review.
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Do not involve the vehicle in crash testing without prior engineering

review.
Prohibit work on any part of the vehicle fuel system.
Ensure any parked vehicle has the fuel shut off at the supply tank.
Refer to Flowchart 3.7.5 Hydrogen Fueled Vehicles in Buildings.
Flow Chart
3.7.5.docx
3.7.5.1 Location
Locate any area intended for housing hydrogen-fueled vehicles adjacent to an

outside wall in a one-story building with no unrelated facilities or normally
occupied spaces (or unoccupied spaces such as false ceilings, mezzanines, etc.)
installed above or below.
Isolate garages from other occupancies by walls having a minimum fire

resistance rating of two hours.
Provide at least two means of egress from any Garage.
3.6.5.3 Ventilation
Ensure air handling systems in open garage areas are capable of 6 air changes
per hour.
Provide the following for rooms where hydrogen fueled vehicles are kept within a
larger garage area:
A ventilation rate of 1 cfm per ft2 (28.32 L per 0.09 m2) of floor area.
Ventilation pickups located within 6 inches of the ceiling.
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Ensure an engineering review is conducted.
Perform air flow tests (with smoke) to verify that there is air movement
throughout the entire room and that there are no dead spaces where
hydrogen could be trapped. Refer to 3.7.1.1 General Conditions – Room
Ventilation.
3.7.5.4 Electrical
Ensure electrical equipment located within 18 inches of the ceiling is classified a

minimum Class I Division 2 (Zone 2).
3.7.5.5 Protection

0.30 gpm/ft2 (12.2 L/min/m2) over the lesser of 3,000 ft2 (280 m2) or the entire
area of application.
Install a hydrogen detection system at the ceiling to provide an alert in the event
of a leak. Arrange the system to alarm at 20% of the LFL.
Note: In very large garage areas, it may not be practical to install a detection
system in the entire building. It may be acceptable to designate an area
where hydrogen vehicles will be located and provide detection in this area.
4.0 RECORDS – N/A
5.0 REFERENCES
NFPA 13 – Standard for the Installation of Sprinkler Systems

NFPA 20 – Standard for the Installation of Stationary Pumps for Fire Protection
NFPA 24 - Standard for the Installation of Private Fire Service Mains and Their
Appurtenances
NFPA 30 – Flammable and Combustible Liquids Code
NFPA 30A – Code for Motor Fuel Dispensing Facilities and Repair Garages
NFPA 33 – Standard for Spray Application Using Flammable and Combustible
Liquids
NFPA 36 – Standard for Solvent Extraction Plants
NFPA 45 – Standard for Fire Protection for Laboratories using Chemicals
NFPA 54 – National Fuel Gas Code
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Level
NFPA 55 – Standard for the Storage, Use and Handling of Compressed Gases
and Cryogenic Fluids in Portable and Stationary containers, Cylinders and Tanks
NFPA 58 – Liquefied Petroleum Gas Code
NFPA 70 – National Electrical Code
NFPA 72 – National Fire Alarm Code
NFPA 77 – Recommended Practice on Static Electricity
NFPA 80 – Standard for Fire Doors and Fire Windows
NFPA 255 – Standard Method of Test of Surface Burning Characteristics of
Building Materials
NFPA 496 – Standard for Purged and Pressurized Enclosures for Electrical
Equipment
GM NAO Piping Systems Identification Standards

09/29/2009 2 Revised Technical Contact
08/04/2010 3 Clarified Fluid Fill Vapor Barrier
Requirements
7.0 DEFINITIONS
Chassis Dynamometer Operations are generally utilized for operating the total
vehicle on roll test beds and dynamometers to evaluate such items as emissions;
vibration; drive train; heating, ventilation and air conditioning (HVAC) and other
systems verification at normal atmospheric conditions. These operations may
also include allied repair facilities.
Engine Hot Test Operations are those in which production engines are cycled
with a fixed fuel piping system to determine operational characteristics prior to
delivery of engine to point of use.
Engine Test Cell Operations consist of severe structural and system testing for
development and durability. The hazards created by this type of testing require
additional protection both for life safety and property conservation. Examples
include high revolutions per minute (rpm), high load, elevated temperatures,
maximum power curve, and experimental components.
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Engineering Review is required for any proposed deviations, new construction,

or process changes and must include representatives from Global Security,
Safety, Industrial Hygiene, and appropriate engineering functions as deemed
necessary.
Environmental Test Chamber Operations contain facilities for engine and

chassis development and durability testing capable of controlling temperature
and atmospheric pressure conditions. Generally, temperature extremes may
range from -40º F (-45.5º C) to 250º F (+60º C) at atmospheric pressures from
below sea level to high altitude. Fuel systems may be fixed or portable.
Hydrogen Fuel Cell Test Operations are those in which fuel cells are cycled
with a fixed fuel system to determine operational characteristics. Fuel cell test
chambers are used to determine power curves and durability at high RPM and
load.
Hydrogen Fuel Fill Areas are approved locations, inside or outside of buildings,
where the process of refilling hydrogen cylinders (outside only) or the changing of
portable hydrogen cylinders is conducted.
Fuel Flow Operations consist of any conditioning carts, tanks, fueling systems,
flow conditions of carburetion, fuel injection, pumps, regulators, related
components and test equipment. These operations are generally conducted
within properly ventilated rooms, enclosures or booths rated for flammable or
combustible liquids with fixed or portable fuel piping systems.
Handling of Fuels at Elevated Temperatures consists of the use of fuel

conditioning equipment to operate at temperatures exceeding ambient
conditions. These conditions are generally associated with various emissions
functions, but may be installed within Environmental Test Chamber Operations.
Fuel systems may be fixed or portable.
Lab Hood Operations are those in which testing is conducted on a small scale
inside an approved laboratory hood. The lab test hoods are ventilated
enclosures designed to contain and exhaust fumes, gases, vapors, mists and
particulate matter generated within the hood interior. Lab hoods are used for the
experimental handling of open containers with small amounts of fuels.
Recirculation Reservoirs are intermediate reservoirs located within the fuel

supply piping, usually equipped with a standard fuel pump, high and low level
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sensors, and an automatic filling system. This reservoir and pump allow for more
consistent fuel delivery during testing.
Research and Development Garages are those areas where experimental

hydrogen/hydrocarbon equipped vehicles fueling systems are either assembled
or disassembled.
Storage Garages are those areas strictly for the storage of vehicles and
equipment.
Vehicle Test Operations are those in which fuel cells and other engines are
cycled with a fixed fuel system (gasoline, hydrogen, compressed natural gas,
diesel fuels) to determine operational characteristics. Vehicle test operations are
used to determine power curves and durability under temperature extremes,
various atmospheric pressures, high RPM, and load.
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8.0 APPENDIX

8.3.1 Computer Rooms
Separation
A security perimeter should exist around the computer room.
Points of access through roof areas over computer rooms should be secured to
prevent unauthorized entry.
Access to the building in which the computer is located should be controlled. It is

desirable that a security perimeter exist around the building or complex of
buildings in which the computer room is located, for the purpose of screening
personnel who have access to this site.
Access to the computer room via tunnels, storm or sanitary sewers or other
means should be secured to prevent unauthorized entry.
Where the computer operations are considered to be critical to the continuity of

operations, computer power should be interlocked to sprinkler system water flow,
provided this will not result in the loss of essential data.
Additional Protection
If the subfloor is protected by CO2, the system should be designed on the basis
of a 50% concentration with a 20 minute hold time and interlocked as necessary
with air handling equipment and computer power. The need for a connected
reserve should be based on risk considerations, such as the critical nature of the
operations and the timeliness (less than 24 hours) of recharge services.
Computer rooms should be equipped with portable carbon dioxide and

pressurized water (clearly marked: “Do not use on live electrical equipment”)
extinguishers. Dry chemical extinguishers should not be used in computer
1 Appendix
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rooms, data storage rooms or in any surrounding support areas where infiltration
of the dry chemical powder is likely.
Remote Computer/Data Processing Locations
The protection provided for these locations should be reviewed by Audit

personnel on a regular basis to determine if changes from the original scope
have affected the classification. An item to review when determining the
criticality of the computer facility is the extent to which services and/or production
would be interrupted should the equipment become inoperable. Another item to
be evaluated is whether or not confidential or proprietary information is
processed, the release of which could cause embarrassment or the loss of a
competitive position for General Motors Company. If the remote computer
location is judged to be either critical or sensitive, fire protection guidelines
similar to a computer room as previously outlined in this Chapter shall be applied.
Metal waste containers equipped with a flame containment device should be

utilized to collect waste paper and trash. An adequate supply of portable fire
extinguishers should be provided.
8.3.2 Engine Test Operations
Any test requirement not in this standard should be evaluated on an individual

basis. The evaluation should be based on acceptable risk and prevention of loss
through the use of increased controls and safety systems. The level of
acceptable risk should be evaluated prior to performing any tests which may not
be covered by a specific code.
8.3.2.1 Engine Hot Test Areas, Chassis Dynamometer Areas and Fuel Flow
Operations
Drains
Size drains sufficiently to handle 1) the maximum possible rate of spillage and 2)
any agent which may be used for the removal of the spilled fuel or the discharge
from fire protection equipment.
Locate drains close to potential points of fuel spillage. The drains should direct
the spilled fuels and other liquids to a safe approved location.
2 Appendix
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Arrange the drains so that liquid in the vertical riser of the drain will remain as
close to the floor level as possible, thereby preventing a major vapor volume. If
this is accomplished by traps, each trap should be vented through a flame
arrestor.
If a large drainage system is used to handle several points of potential fuel

spillage, all main conduits of the system should be kept flushed.
Piping
Fuel accumulated in an outside receiving tank may be pumped back to the main
supply tank or disposed of under controlled conditions.
Piping should be banded, tagged or otherwise marked to indicate contents and

direction of flow. Piping systems should be compatible with the fuels used.
Compressed natural gas piping should be clean internally and free of chips, scale
or other foreign matter.
Fuel lines should utilize a positive shut off valve and be capped or plugged
whenever disconnected. Abandoned or unnecessary fuel piping not in service
should be purged or removed.
Where piping in a building is exposed and under pressure, and a safety device
shuts off a fuel pump or pumps, a solenoid valve or valves should open to
provide pressure relief and drainage of fuel back to storage or outside receiving
tanks.
Piping should be designed to avoid the use of sealants and gaskets. When
required, sealants and gaskets should be compatible with the fuel within the
system.
Prohibit fuel lines to run through basements, tunnels, trenches or pits without
adequate ventilation and drain lines to interceptor tanks.
Flexible Lines, Fittings, and Connections
Proper hose routing and installation methods should be in accordance with the
manufacturers recommendations.
3 Appendix
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Non-permanent connections should be equipped with a positive disconnect

closure valve to seal the supply line before the connection is broken.
Fuel Delivery
Liquid fuel should not flow by gravity from the tank farm to the test area, except
from day or header tanks, unless interceptors are sized to accept the maximum
possible leakage.
Recirculation reservoir systems are acceptable, but should be as small as is

practical. Reservoirs larger than two gallons (7.6 L) require Global Security
review.
Pumps and Pump Rooms
Install distribution pumps in detached shelters equipped with approved

mechanical ventilation.
Floors of distribution pump rooms should be pitched to enable spilled liquids to

drain to outside containment or to interceptor tanks.
There should be no pits or tunnels below distribution pump rooms.
Fuel lines in distribution pump rooms should be placed in the open.
Provide each fuel supply tank with a separate distribution pump.
Where pump relief valves are employed for liquid fuels, they should be piped to
the fuel supply tank to which the pump is connected. Relief valves for
compressed natural gas systems should be vented to the atmosphere at a height
greater than adjacent buildings.
Design pumps and associated piping to be compatible with the fuels used.
Provide a remote emergency means, exterior to the pump rooms or test cells, to
shut off the flow of fuel from the distribution pumps.
8.3.2.1.3 Ventilation
Room Ventilation
4 Appendix
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Arrange ventilation so as to maintain a pressure lower than any adjoining building

area. Dependence should not be placed on natural or gravity ventilation.
Ventilation required in excess of one cfm (28.32 L) should be a matter of

individual study, with special consideration given to fuel characteristics and heat
dissipation.
If a mechanical system of air supply is required, the air supply should be placed
near the periphery of the area. Depending on the fuel characteristics, i.e., fuels
lighter than air, room ventilation systems may need to be modified to exhaust
near the ceiling as well as near the floor.
Monitor the ventilation through the use of contactors, motor starter interlocks and
air flow monitoring devices.
Engine Exhaust
Exhaust ducts should be connected to the engine or chassis exhaust outlet at all
times during engine and chassis operations to prevent discharge of carbon
monoxide into the room atmosphere.
Since exhaust ducts become hot during engine operation, fuel lines should be
effectively segregated from the ducts by suitable distance, adequate thermal
insulation or a combination of distance and insulation.
Determine the rate of engine exhaust ventilation for the largest engine on test
and operating at maximum speed. The vehicle exhaust evacuation system
should maintain a negative pressure with respect to room ventilation. Branch
ducts should be well designed with proper angle of entry.
Where diesel engines are tested, care should be taken to mitigate fires in the
engine exhaust ducts. This may require the addition of outside air to dilute the
residues to a safe level.
Trenches should be covered completely, except for pre-selected air openings, to

assure that all parts of the trench are flushed out by the movement of air to the
point of exhaust.
5 Appendix
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Test Area Equipment and Wiring
No alterations should be made to electrical wires or connection which might

affect the ventilation or fire protection devices without the approval of the WFG,
Security and Safety representatives.
8.3.2.1.5 Hazard Control Equipment
Where there is a critical need to protect the control equipment associated with
test functions, the control room concealed floor space should be arranged or
protected as indicated in 3.1.
Inside hose connections should be provided in accordance with the applicable

provisions of Chapters 2 and 5 of this manual.
Welding, open flame and sparks should be avoided. If these operations are
necessary, the applicable provisions of Chapter 1, Section 3.4 of this manual
should be followed.
8.3.2.2 Engine Test Cells and Environmental Test Cells
Portable Fuel Systems for Environmental Test Cells
Where test conditions require that both the fuel and the chassis/engine should be
conditioned with respect to changes in temperature, portable fuel systems may
be employed.
Portable containers should be of the type approved for flammable liquid storage
and handling.
The amount of liquid fuel to be kept in the environmental test cell for conducting
engine tests should not exceed five gallons (18.9L).
The amount of liquid fuel in the chassis gas tank should be kept to a minimum
consistent with the test program.
No surplus fuels or liquefied gases should be stored in an environmental test cell.

Safety cans should be piped to the engine with threaded connections. Self-
sealing disconnect means are recommended.
6 Appendix
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8.3.2.4 Compressed Gas Bottle Storage and Use
The following operations are included for storage and distribution of compressed
gases:
Engine and Vehicle Emissions Analysis
Materials Labs Analysis Equipment, including Gas Chromatograph and

Flame Ionization Detectors
Families of gases used in the above areas include;
Flammables - carbon monoxide, hydrogen, methane and propane,

Toxic - oxides of nitrogen, carbon monoxide and hydrogen sulfide,
Inert - nitrogen and carbon dioxide,
Oxidizers - oxygen,
Non-flammable - zero air
(Note: a variety of blends of the above named gasses is typical)
The location and layout of compressed gas storage should be made in

conjunction with the facility WFG representative and should be reviewed by the
Safety and Security Departments.
Existing installations which do not conform to the recommendations contained in

this Chapter should be upgraded where the discrepancies are recognized
hazards to life or property, or they conflict with enforceable government
regulations.
Regardless of the inherent safety designed and built into an installation, fire
prevention and safety depend on thorough training of personnel combined with
scheduled follow-up and refresher programs, constant supervision, continuous
maintenance and inspection, and good housekeeping programs in all phases of
the operations.
Location and Construction
Access for receiving deliveries should be provided to minimize traffic through

other occupancies.
7 Appendix
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Materials used in construction should be in accordance with Chapter 4 of this

manual, and should be resistant to accumulation of flammable and combustible
materials which may provide a “wick” effect.
Pits or trenches should be avoided.
All rooms should have a grounded, non-sparking conductive floor coating and a
perimeter grounding bar.
Separation of flammable, toxic and oxidizer gases should be maintained by either

distance or a fire rated barrier.
8.3.2.4.2 Distribution Piping
Installation and labeling methods should comply with ANSI B31.3, A13.1,
General Motors NAO Piping Systems Identification Standards SD 3-95 and
applicable building codes.
Piping or tubing should be routed to prevent physical damage and to minimize

the exposure to occupied areas. Where the piping or tubing must be routed
through occupied areas, additional measures should be taken to prevent
exposure to leaks.
8.3.2.4.5 Hazard Control
At no time should smoking or the use of open flame be permitted in areas where
flammable gas vapors are present.
Welding, open flame and sparks should be avoided. If these operations are
necessary, the applicable provisions of the Chapter 1, Section 3.4 of this manual
should be followed.
Continuous monitoring for gas leaks should be provided for combustible and/or
toxic gases stored within the facility.
8.3.2.A Ventilation Equations
This embedded document provides equations that may be used to help

determine the amount of ventilation required within a test cell area.
8 Appendix
Level
Ventilation
Equations
8.3.3 Outside Storage of Fuels
Aboveground Tank Storage
Regulations by the Environmental Protection Agency (EPA) in the United States

and similar organizations elsewhere regarding underground tank storage have
resulted in many installations being relocated to an aboveground arrangement,
creating additional fire exposures.
Special situations such as large groups of tanks with inadequate spacing

between tanks or other exposures may require more than one form of protection.
See XL GAPS Standards and Guidelines GAP.8.2.0.1 for further guidance.
Since there is a greater emphasis on the replacement of buried tanks with

aboveground tanks, open top pits or open top vaults, this document provides
guidance for planning adequate fire protection. If pits are totally enclosed, they
are considered to be tank storage inside buildings.
Special conditions such as large groups of tanks which cannot be properly

separated by the minimum distances in Table 3.3.a may require additional
exposure protection. These installations should be reviewed with the Global
Security Staff to assure adequacy of protection for these special conditions.
Liquefied Petroleum Gas
Experience has indicated that distance between unloading stations, vaporizers,

storage tanks and major buildings are critical with regard to the extent of potential
fire involvement. As indicated in Table 3.3.b, the order of fire protection
preference for LPG tanks is:
1. Buried or Mounded
2. Water Spray or Insulate
9 Appendix
Level
3. No Special Protection
Groups of tanks totaling over 60,000 gallons (227,100 L) should not be installed
without some form of special protection.
8.3.4 Fluid Fill Operations
Spill Control
Fluids recovered by the fuel/water separator should be transferred in accordance

with accepted practices. The separator should be located 10 ft. (3.0 m) inside
the length of the vapor barrier, or properly partitioned from any unclassified area.
The separator fuel containment chamber should not exceed 50 gallons (189.3L)
and should have over-fill protection and alarm. There should be secondary
containment for the separator with a capacity of 110% of the fuel containment
chamber. All electrical equipment should be rated for the intended use.
A high fluid level alarm should be provided for the sump collection point and
storage tank to prevent overflow into adjacent areas.
Tanks or containers of flammable or combustible fluids that are located adjacent

to the fluid fill area water wash system should have spill containment.
Fluid portable tanks that are not located adjacent to the fluid-fill area water wash
system should have spill containment. A means for detecting fluid leakage
should be present and should initiate an alarm within the spill containment area.
Piping and Tubing
Components used in the processing, transferring or dispensing of fluids should

be chemically compatible with fluid in use.
All hoses used for the transferring or dispensing of fluids should be chemically
compatible and have the capability of dissipating static electricity.
Fluids should be drawn from portable tanks through an opening in the top using
an anti-siphon valve.
Electrical
10 Appendix
Level
The vapor barrier will normally extend 15 ft (4.57 m) beyond the mechanical
ventilation. However, in instances where the mechanical ventilation extends
more than 10 ft (3.05 m) beyond the dispensing area, the vapor barrier need not
extend the full 15 ft (4.57 m) beyond the mechanical ventilation. The vapor
barrier must extend 25 ft (7.62 m) beyond the dispensing area.
It is recommended that the vapor barrier be extended to 48 inches (1.2m) in

height, either by means of a railing or solid material to prevent a tripping hazard.
All portable tanks should be bonded or connected to ground by pressure-type

ground clamps, battery-type clamps, magnetic clamps, or other special clamps
that provide metal-to-metal contact.
8.3.4.3 Fire Protection and Prevention
Water flow supervision should be provided for the dedicated sprinkler protection
in the dispensing area.
Detection
At least one detector should be provided outside of each fluid-fill area pit barrier
opening, and in accordance with the manufacturer's specifications for the
application. The detectors should initiate a trouble signal locally, and to the
proprietary alarm console, at 20% of Lower Flammable Limit (LFL). The
detectors should initiate an alarm signal locally and to the proprietary alarm
console, and initiate an emergency shutdown at 40% of the LFL.
Emergency Manual Pull Stations
Pull stations should be located a bay away up line, and a bay away down line, of
the fuel-fill operation.
The emergency stop buttons should be clearly marked.
The emergency stop buttons should be interlocked to close “fail safe” electrically
supervised shut off valves located as follows:
In the fuel distribution piping at the metering station
11 Appendix
Level
In the trusses, one to two bays from the metering station
Interlocks & Proprietary Signaling
Each plant should have a specific matrix developed to cover the individual
operation.
All fire protection interlocks should be hardwired to the process equipment.
The fluid dispensing area fire protection alarm system should be listed/approved
by a nationally recognized testing lab as “Automatic Extinguishing and Releasing
Equipment”.
Trained personnel should conduct testing of the system functionality and

interlocks.
Operations
A "Sequence of Operation" should be developed for the entire fuel

delivery/dispensing system and posted in the area for reference. Periodic training
is recommended for area employees and security staff regarding normal and
emergency operation of the system.
The restricted ignition sources should include, but are not limited to, cell phones,
portable electronic devices, cutting, burning or welding.
Process Equipment Requirements
Any proposals for use of specially designed fuel-fill nozzles for On-Board Vapor
Recovery Systems require additional review.
Vapor recovery and/or incineration (catalytic oxidation) equipment should be

located outside the building. If a supplemental vacuum source is used it should
be located inside the classified operational area.
8.3.6 Material Storage
Yard Storage
Empty metal racks without dunnage or combustibles of any type can be used as
fire breaks in order to exceed the 2,500ft2 {232.5m2} pile size limitation. The
12 Appendix
Level
firebreaks should be arranged in accordance with the aisle width requirements. If

the noncombustible firebreaks are used, the overall pile size should not exceed
10,000ft2 {930m2}.
8.3.7 Operations Involving Hydrogen Fuels
General Conditions
8.3.7.1.3 Protection
Additionally, the test cell audible alarms and strobes can be actuated manually at
a local control panel or by activation of the E-stop.
Avoid welding, open flame and sparks. If these operations are necessary, the
applicable provisions of Chapter 1, Section 3.4 should be followed.
Lab Hood Operations
8.3.7.3.2 Room Ventilation
The typical laboratory hood should operate under negative pressure with face
velocities ranging from 80-120 linear ft/min (0.41-0.61 m/sec), with 100 linear
ft/min (0.5 m/sec) being most common.
Exhaust stacks should extend at least 10 ft (3 m) above the highest point of the
roof.
It is recommended that electrical receptacles be located outside of the hood.
13 Appendix
3.7 - Operations Involving Hydrogen Fuels
Yes
Will the hydrogen
Requirements as outlined in
be used in a lab?
Section 3.7.3
No
Will the hydrogen Yes Will the work Yes

be in a test cell or involve any part of
single vehicle the hydrogen fuel Section 3.7.2
enclosure area? system?
No
No
No Is this a hydrogen
fueled vehicle?
Yes
Section 3.7.5
Is the hydrogen Yes Will the work Yes

use, or vehicle, in involve the
an open building hydrogen fuel Section 3.7.4
area? system?
No No
Engineering review is Requirements as outlined in

needed Section 3.7.5
8.3.7.5 - Hydrogen Fueled Vehicles in Buildings
Vehicle in open No Yes

garage area? Vehicle in display Purge Hydrogen from vehicle or
area? follow Section 3.7.5
No
Yes
Yes Follow Section 3.7.4

Will work involve Or
fuel system? Engineering review is
required
No
No Engineering review required

Section 3.7.5 Remove fuel from vehicle
Guidelines met? Or
Modify facility as required
Yes
No Vehicle can be driven into building

Will vehicle be Shut off fuel supply at tank
running in place? Vehicle can be parked or serviced
Yes
Will vehicle be on No Vehicle equipped Yes

a dyno, shaker or with onboard H2 Vehicle can be run in
other test stand? detection and fuel building
isolation?
Yes No
ABOVEGROUND TANK STORAGE OF FLAMMABLE AND COMBUSTIBLE LIQUIDS
CLASS I LIQUIDS
TABLE 3.3.a
Distance to Important Diking per Outside Yard Fixed Protection

Total Capacity of all Tanks
Buildings NFPA 30 Protection (AFFF/Waterspray)
gallons liters > feet > meters Yes/No Yes/No Yes/No
0-250 0-947 5 2 N1 Y N
1
251-1,000 950-3,785 15 5 N Y N
2
1,001-50,000 3,790-189,271 50 15 Y Y N6
>50,001 189,274 > 100 > 30 Y2 Y N6
>50,001 189,274 < 1004,5,6 < 30 Y2 Y N6
CLASS II AND III LIQUIDS

0-1,000 0-3,785 5 2 N1 Y N
2
1,001-5,000 3,790-18,927 15 5 Y Y N
2
5,001-100,000 18,931-378,541 50 15 Y Y N
2
> 100,001 > 378,545 > 100 > 30 Y Y N
> 100,001 > 378,545 < 1004,5 < 30 Y2 Y N3,6
NOTES
1. Diking may be required to protect buildings, access roads or for environmental purposes.
2. Intermediate diking which is at least 18 inches (0.5 meters) high is required within diked areas for each group of two or more tanks of Class I liquids or for
each group of four or more tanks of Class II and III liquids.
3. Portable foam application as minimum.
4. In no case less than 50 ft. (15 m) with consideration for prevailing wind.
5. Includes open vaults which have the tanks below or above grade. In no case less than 25 ft. (7.5 m) with consideration for prevailing wind.
6. Tank unloading station shall be protected if distance to important buildings is less than required for the tank farm.
ADDITIONAL REQUIREMENTS
1. The requirements for Class I liquids should be followed for combined tank farms.
2. Where Class I is segregated from Class II and III by barrier wall to top of tank heights within the same tank farm, fixed AFFF/water spray may
be omitted for Class II and III.
LIQUEFIED PETROLEUM GAS INSTALLATIONS
MINIMUM SPACING FOR LPG TANKS BASED ON PROTECTION LEVEL
TABLE 3.3.b
Major Buildings, Tank Farms, Etc.
Distance to Other Wall Distance to Distance

Capacity Distance to Masonry Constructions or Open Sources of Distance Distance to to Other
gal./group Walls Non-combustible Buildings with Ignition, Boilers, to Unloading Groups
of tanks Walls No Basements Basements Furnaces Vaporizer Riser of Tanks
(liters) Equipment ft. (m) ft. (m) ft. (m) ft. (m) ft. (m) ft. (m)
Buried or Mounded(1)
30,000 Tanks 50 (15) 200 50 (15) 50 (15) 25 25
to
180,000 Direct/indirect fired-75 (23) Direct/indirect fired-75 (23)
(113,562 Vaporizer 75(2) (23) -- 50 (15) 50 (15)
Steam-45 (13.7) Steam-45 (13.7)
to
681,374) Unloading Riser 75 (23) 75 (23) 75 (23) 50 (15) -- 50 (15)
(3) (4)
Water Spray or Insulated
30,000 Tanks 100 (30.5) 300 (91.4) 75 (23) 50 (15) 50 (15) 75 (23)
to
Direct/indirect fired-75 (23) Direct/indirect fired-75 (23)
180,000 Vaporizer 75(2) (23) -- 50 (15) 50 (15)
Steam-45 (13.7) Steam-45 (13.7)
(113,562
to 75 (23) [or 50 (15) with
681,374) Unloading Riser water spray on platform 75 (23) 75 (23) 50 (15) -- 50 (15)
and tank cars and trucks]
No Special Protection
<30,000 gal. – 100 (30.5)
Tanks 30,001-60,000 – 150 (46) 300 (91.4) 100 (30.5) 75 (23) 75 (23) 75 (23)
Up to >60,000 – Special Protect.
60,000 Direct/indirect fired-75 (23) Direct/indirect fired-75 (23)
(227,125) Vaporizer 75(2) (23) -- 50 (15) 50 (15)
Steam-45 (13.7) Steam-45 (13.7)
Unloading Riser 75 (23) 75 (23) 75 (23) 50 (15) -- 50 (15)
(1) Minimum of 2 feet of bury over top of each tank. Tanks must be properly coated. Note: Certain "authorities having jurisdiction" do not allow this concept.
(2) Heaters for indirect vaporizers may be located adjacent to but in cut-off rooms.
(3) Water spray protection on the basis of 0.30 GPM (12.2 L/min/m2) for all tank surfaces including tank cars, tank trucks and unloading platforms. Monitor nozzles acceptable for existing
installations; however, new installations should use the other forms of protection.
(4) Note: Water spray is preferred over insulation.
FLUID FILL PROCESS AND ALARM INTERLOCKS
Table 3.4.3.4
FIELD DEVICE
INTERLOCK PROCESS EQUIPMENT INTERLOCKS SIGNALS TO BUILDING PROPRIETARY SYSTEM
Manual Fuel Dispenser

Diesel Supply Shut off
Test Mode to Building
Manual Pull to Building

Washer Fluid Shut off
Field Mounted Signal
Fuel Water Separator
Gas Detector High LFL

Fuel System Control
Gas Supply Shut off
GAS DETECTION FAULT TO
Gas Detector Low LFL

Conveyor Iinterlock
Windshield Washer
General Trouble to
Air Supply House
General Alarm to
Air House Alarm to

Valve Close
Valve Close
Valve Close
Fluid Panel
Sprinkler Flow to
Interlock
Building
Building
Panel
to Building
to Building
Building
Building
BLDG
INPUT DEVICE
Manual Pull Station X X X X X X X X X X X X
Exhaust Air Not Proven X X X X X X X X X X X X
Supply Air Not Proven X X
Pit Sump High Level X X
Area Sprinkler Flow Switch (e.g. pit, stack,

duct mezzanine) X X X X X X X X X X X X
Pit X
Stack X
Duct X
Combustible Gas Detector Fault X X X
Combustible Gas Detector Low (20% LFL) X X X
Combustible Gas Detector High (40% LFL) X X X X X X X X X X X
Air Supply House Smoke Detector Alarm X X X X X X X X X X X X
Control Panel Loss of AC Power X X
Control Panel Battery Disconnect Open X X
Control Panel Bypass Switch (e.g. waterflow,

pull station, smoke det., LEL det.,vent.) X X
Water Flow X
Pull Station X
Smoke Detector X
LEL Detector X
Ventilation X
table 3.4.3.4
FLUID FILL PROCESS AND ALARM INTERLOCKS
Table 3.4.3.4
Control Panel General Trouble (process fault,
communications fault, etc) X
table 3.4.3.4
EQUATIONS FOR USE IN DETERMINING VENTILATION RATES IN
ENGINE TEST CELLS OR FUEL HANDLING AREAS
In determining the necessary ventilation required for safe operation of engine test cells
and other areas where fuel spills are possible, it is beneficial to look at the potential
situations quantitatively. The amount of air required will depend in a large part on the
possible amount of fuel spilled and the speed at which the fuel would evaporate. The
equations in this section will help in estimating the amount of air needed to dilute vapors
from a potential fuel spill to a mixture that will not ignite. (NOTE! These calculations are
approximate). The safety factors used when applying these equations should vary
relative to the potential for an accident.
The following values, used in the calculations, are at pressure = 29.92” Hg and
temperature = 70º F (P = 0.76 m HG, T = 21º C):
air density = 0.075 pounds per ft3 (1.2 kg/m3) 1.199 kg/m3
air equivalent molecular weight = 28.97
air vapor density = 1.0
1 gallon water = 8.35 pounds of water (1 Liter = 1 kg)
water specific gravity = 1.0
The example calculations are for gasoline, using the following average values as those
for gasoline vary widely.
gasoline (API = 60) specific gravity = 0.739
gasoline molecular weight approximately = 111
gasoline vapor density approximately = 3.8
lower explosive limit of gas in air (approximate) = 1.4 percent
Note: Values used in actual calculations should be those obtained from the Material
Safety Data Sheets for the fuels to be used in the test cells.
The following abbreviations are used in the calculations:

D = Density Dv = Vapor Density
L = Liters LEL = Lower Explosive Limit
MW = Molecular Weight SG = Specific Gravity
V = Volume Vl = Liquid Volume
Vv = Vapor Volume W = Weight
The following steps should be followed in order to calculate the approximate minimum
rate of ventilation required to maintain fuel vapor concentrations below minimum safe
levels:
Step 1. If the vapor density of the fuel is not known, it can be determined from the
molecular weight using the following formula:
Dv = MWfuel / MWair
Example: Dv (gasoline) = MWgasoline /MWair = 111 / 28.97 = 3.8

Step 2. Determine the volume of vapor possible from a volume of liquid using the
following formula:
Vv(fuel) / Vl(fuel) = (Wwater / Dair) x (SGfuel / Dv(fuel))
Example:
Vv / Vl = (8.35 lbs/gal /0.075 lbs/ft3) x (0.739/3.8) = 21.65 ft3/gal
or Vv / Vl = (1 kg/L / 1.2 kg/m3) x (0.739/3.8) = 0.16 m3/L
Step 3. Determine the volume of air required to bring the air/vapor mixture to the
LEL using the following formula:
Vair / Vfuel = (Vv(fuel) / Vl(fuel)) x (100 – LEL) / LEL
Example: Vair / Vfuel = 21.65 ft3/gal x (100-1.4) / 1.4 = 1,525 ft3/gal
or Vair / Vfuel = 0.16 m3/L x (100-1.4) / 1.4 = 11.3 m3/L
Step 4. Determine the volume of air required to bring the air/vapor mixture to 20%
of the LEL, the typical first warning level, as follows:
Multiply the volume of air determined in Step 3 by five
Example: 1,525 ft3/gal x 5 = 7,625 ft3/gal
or 11.3 m3/L x 5 = 56.5 m3/L
Step 5. Approximate the ventilation rate required to maintain the air volume
mixture below the LEL.
The first factor to consider is the rate of vaporization of the fuel. A

reasonable example would be gasoline dripping on a manifold and
vaporizing instantly at a rate of 0.25 gal (0.95 L) per hour.
Example: (7,625 ft3/gal) x (0.25 gal/hr) x (1 hr/60 min) =31.8 cfm
or (56.5 m3/L) x (0.95 L/hr) x (1 hr/60 min) = 0.9 m3/min
This may seem an inordinately small amount of dilution air, but that may be because all
of this ventilation must be directed at the area of spill in order to be effective. The
ventilation rate for the room as a whole would need to be higher to ensure that the
minimum rate is available at anticipated spill locations. Other major factors to consider
when designing safety ventilation are possible rate of fuel spill, possible rate of
vaporization, locations of possible spills, and exhaust ducting proximity to the expected
level of fuel vapor accumulation.
Building Construction
Level
1.0 PURPOSE
This chapter provides standards and additional information regarding building

construction as it relates to fire protection.
2.0 SCOPE
The following standards assist in ensuring GM facilities are constructed with
materials that will support the level of safety and property conservation needed.
The requirements listed in this Chapter apply to GM owned and managed

facilities globally. Applicable local regulations may supersede the GM standards.
3.0 STANDARDS
3.1 Construction Materials
Provide new building construction assemblies and components that are

noncombustible (i.e. Class A, Class I, Flame Spread < 25) or fire resistive and
comply with local codes and standards. Combustibility ratings applied to such
materials must be supported by fire testing and acceptance by a recognized
testing laboratory.
See also the Worldwide Facilities Group, Capital Projects, GM One Spec Facility
Construction Specification for details regarding construction.
Atypical building materials or types of construction (e.g. tents, temporary

buildings and air supported structures), must be approved by local authorities
having jurisdiction and by Global Security.
3.2 Roofs
Do not use combustible materials for roof decks of new buildings.
Ensure all roof assemblies have a Class “A” exterior fire exposure rating as
defined by the Underwriters Laboratories, Inc., Factory Mutual Research
Corporation or other recognized testing laboratories.
3.3 Walls/Barriers/Separation
3.3.1 Wall/Barrier Construction
1
Level
3.3.1.1 Insulated Panels

Acceptable foamed plastic-filled wall construction for use as interior panels,
modular panels, and exterior siding are limited to the following types:
Those identified in Underwriters’ Laboratories, Inc. Building Materials

Directory as “Insulated Wall Constructions (NYVQ)”
Those identified in Underwriters’ Laboratories, Inc. Building Materials

Directory as “Interior Building Constructions (OEQX)”
Those identified in Factory Mutual Approval Guide as “Walls, Insulated

Core - Class “I”
Those identified by other recognized testing and approval agencies for

wall construction.
3.3.1.2 Foamed Plastic Materials
Any interior applications of foamed plastic materials, such as urethanes or

polyisocyanurates, should be Class “A” rated in accordance with manufacturer’s
specifications including a 15 minute fire/thermal barrier.
3.3.1.3 Draft Curtains
Draft curtains, where required, must be constructed of non-combustible material

and must not allow passage of air. Do not use sheet metal of less than 20 MSG
(0.912 mm) gauge in thickness.
3.3.2 Plant Area Separation
Separate office buildings from adjoining manufacturing areas with a minimum

one hour rated fire barrier partition wall with protected openings. Where the
office building is not protected by automatic sprinklers, a two hour rated barrier is
required.
Segregate high-piled warehousing (storage 12 ft. (3.7 m) and higher) into

maximum fire areas (separated by fire walls) of 500,000 ft2 (46,500 m2).
Protection requirements and other guidelines for warehousing and storage can
be found in Chapter 2, 3.6, Warehousing.
2
Level
3.4 Exposures
Off-premises and on-premises exterior hazards such as, aboveground flammable

liquid storage tanks or yard storage of pallets, must be given consideration when
determining facility construction and protection requirements.
4.0 RECORDS – N/A
5.0 REFERENCES
Worldwide Facilities Group, Capital Projects - GM One Spec Facility Construction

Specification

Contact
7.0 DEFINITIONS – N/A
3
Level
8.0 APPENDIX

8.3.1 Construction Materials
There will be limitations as to the degree to which a building code can be applied
to existing structures. However, in the case of existing buildings, there may be
certain improvements that are necessary to achieve overall fire safety.
There is an ever increasing variety of building materials and types of

construction. The information in this Chapter does not cover all types of
construction employed by GM.
8.3.2 Roofs
Precast Concrete or Other Nonmetallic, Non-combustible Prefabricated Deck

Units
All joints should be sealed to prevent hot bitumen from dripping in the event of
fire. All joints are covered with strips of asphalt-coated organic felt set in roof
cement. An underlayment of two plies of asphalt glass felt is applied to the deck
in hot asphalt. Board type insulation made of glass fiber, polyisocyanurate, wood
fiber, mineral products, or other material is applied directly to the underlayment in
a full mopping of hot asphalt. A second layer of insulation may be applied to the
first in a full mopping of hot asphalt. A Class “A” roofing membrane is then
applied to the insulation.
Metal Form Deck with Poured-In-Place Inert and Non-combustible Lightweight

Concrete
Roofing is installed on board type insulation of minimal thickness in hot asphalt

on a fastened underlayment of asphalt coated glass fiber base sheet.
Standard Metal Roof Decks Covered with a Non-combustible Type of Vapor Seal
Membrane
1 Appendix
Level
Board type insulation made of materials listed above is applied over the metal
deck, with mechanical fasteners at a rate of one per two sq. ft. of insulation area.
A second layer of insulation may be applied to the first in a full mopping of hot
asphalt. A Class “A” roofing membrane is applied to the insulation. Metal deck
roof construction and all materials used therein should meet the requirements for
metal deck constructions in the Underwriters Laboratories, Inc. Roofing Materials
and Systems Directory and the Factory Mutual Approval Guide that are classified
as to spread of fire on the underside of the deck and/or resistance to uplift forces.
Equivalent ratings by other recognized testing laboratories may also be
considered upon acceptance of Global Security.
Emergency Roof Ventilation (Heat and Smoke Ventilation)
In fully sprinklered buildings, where sprinkler systems are adequately designed,

full scale fire testing has demonstrated that heat release by venting and the
restriction of smoke spread by draft curtains are of limited effectiveness in
controlling damage to buildings and contents.
However, for life safety considerations, some venting is still considered

necessary. In most instances this should be accomplished using powered vents
at a ratio of 1.5 cfm/ft2 (0.45 m3/min/m2). These vents can be designed in
concert with the building HVAC system or may be the stand alone type.
Operation of the vents should preferably be arranged in zones corresponding to
the sprinkler systems. Controls for the manual vents should be readily
accessible.
In multiple story structures such as office and engineering buildings, the HVAC
system should be utilized to accomplish venting through pressurization,
shutdown, exhaust, zoning or other specific smoke control features.
In certain high hazard manufacturing occupancies such as heat treat and engine
hot test operations, venting and deep draft curtains should be installed. Draft
curtains and closely spaced sprinklers should be installed around conveyor or
other large floor openings. Draft curtains may also be required at points where
there are substantial changes in roof elevations and between sprinkler systems
with different response factors (e.g. ESFR and standard sprinklers).
In areas where vents and /or draft curtains are required, the following conditions
should be met:
2 Appendix
Level
Vents or monitors should be spaced so that the distance between sides of

adjacent units does not exceed 80 ft. (24.4m)
The minimum effective vent to floor area ratio should be 1 to 50.
Roof vents should be located at or near the center of small rooms or draft
curtained areas less than three bays. In larger areas, vents should be located
symmetrically, in regular patterns and spacing.
8.3.3.1.1 Insulated Panels
Appropriate precaution during welding and burning operations should be used.

Holes through the siding should be cut with a saw rather than a torch. Panel
assemblies should only be used in their intended orientation as defined by their
testing and listing restrictions. For example, roof panels should not be used for
wall applications. In addition, these panels should not be used in high heat areas
(foundries or oven areas).
8.3.3.1.3 Draft Curtains
Since the centerlines of continuous vents, monitors or sawtooths can be

considered as divisions between draft curtain areas, buildings with continuous
vents, monitors or saw tooths only require transverse draft curtains. Draft
curtains, however, should be continuous across all vents or monitors.
Consideration should be given to correlating sprinkler system areas with draft
curtain areas only to the extent found to be practical in new building construction.
Such correlation in existing buildings generally does not warrant the cost of the
necessary changes.
8.3.3.2 Plant Area Separation
Extra Hazard Areas
Certain extra hazard areas such as flammable liquid storage, paint mix and
storage rooms, polyurethane storage and tire storage, should preferably be
located in separate buildings. If placement is necessary in the main structure,
these rooms should be located in accordance with the applicable chapters of the
General Motors Global Security Manual, Fire Prevention and Protection Section,
and model building codes.
3 Appendix
Level
Extra hazard areas should not be located adjacent to, under or over cafeterias,
toilet rooms and other enclosed areas where employees might be trapped in
case of fire.
The size of any single building area should be determined by referring to local
standards and considering the following factors:
Egress of building occupants
Occupancy, i.e., manufacturing, warehousing, assembly, etc.
Isolation of high hazards
Business continuity
Light and Ordinary Hazard Areas
These areas do not need to be subdivided into fire areas, except as determined
by the Authority Having Jurisdiction or management with regard to single source
plants or other critical or unique processes with substantial business interruption
potential.
4 Appendix
Fire Protection Systems and Equipment
Level
1.0 PURPOSE
This chapter provides standards and additional information with regard to fire
protection systems and equipment.
2.0 SCOPE

3.0 STANDARDS
3.1 Water-Based Systems
3.1.1 Water Supplies
Provide at least one independent and reliable source of water supply for sprinkler
systems and all other fire-fighting equipment.
The water source must be both adequate and reliable in duration, volume, pressure
and rate of flow to meet the highest fire challenge on the property.
Depending upon the size, hazard, values and criticality of the facility, a second
water source may be required. Size this source to match the primary source to
ensure the necessary redundancy.
Duration
For facilities of 100,000 ft2 (9,300 m2) or less, the duration of each required
water supply must be at least 60 minutes.
For facilities of greater than 100,000 ft2 (9,300 m2), the duration of each
required water supply must be at least 120 minutes.
Factors such as plant size, hazard, value, and availability of municipal services may
dictate water supplies of greater duration.
Water Storage Facilities
1
Level
Where the public water system alone cannot be considered an adequate and
reliable water source, appropriately sized ground level tanks, reservoirs or other
sources of supply are required.
3.1.2 Fire Pumps
Fire pumps are required anywhere the public water system cannot satisfy the sum
total of the following:
The single highest sprinkler system hydraulic demand.
An additional 10% allowance for hydraulic imbalance.
The simultaneous hose stream demand.
Fire pumps must be sized based on the above requirements.
Depending upon the size, hazard, values and criticality of the facility, a second
pump and supply may be required. The pump must be sized to match the primary
pump to ensure the necessary redundancy.
Provide dual discharge lines into the fire protection underground system where
multiple fire pump installations are arranged within a single pump house.
Fire pumps and drivers must be listed by a recognized testing laboratory.
3.1.3 Water Supply Distribution
The water supply facilities must discharge into an underground piping system of
sufficient size to supply the highest anticipated water demand for the hazards
involved.
Depending upon the size, hazard, values and criticality of the facility, it may be
necessary to loop the underground piping, or ring main, around each major
building.
Loop piping where any dead end portion of the underground supplies more than a
combined total of five sprinkler risers and/or hydrants.
2
Level
Valves
Provide sectional control valves on the underground distribution piping such that
there are no more than a combined total of five sprinkler risers and/or hydrants
between valves.
Provide a control valve for each sprinkler system. This may be either a post
indicator valve (PIV) on the lead-in piping or a valve on the sprinkler system riser.
Lead-Ins
Size sprinkler system lead-in piping based on the maximum hydraulic demand of
the system, but no smaller than 6” (150 mm) in diameter.
Hydrants
Supply a sufficient number of yard hydrants for hose stream protection for exterior
areas of all buildings.
Locate hydrants so that the required hose streams can provide an adequate
concentration of water for any building or group of buildings, with spacing not to
exceed 500 ft. (152 m).
All hydrants must be of a type approved by the authority having jurisdiction.
3.1.4 Sprinkler Systems
3.1.4.1 General Requirements
Complete automatic sprinkler protection supplied from the outside underground

water main must be provided in all buildings and areas as required by Chapters 2
and 3 of this manual.
Design sprinkler systems in accordance with the occupancy provisions of Chapter

2, or as indicated in Chapter 3 for specific hazards.
Use only ordinary temperature rated 135º F – 170º F (57º C - 77º C) sprinklers,
except in those areas where the ambient temperature dictates the use of higher
temperature heads.
3.1.4.2 Manifolding of Sprinkler System Risers
3
Level
Manifolding of sprinkler risers is permissible if all of the following requirements are

met:
A separate valved connection to the underground water main must be

provided at each end of the manifold.
.
Additional sectional control valves must be installed such that no more than
four systems will be affected by a single impairment.
Each riser must have a separate system control valve.
3.1.5 Hose Systems
Interior Fire Hose
Connect 100 ft (30.5 m) maximum lengths of fire hose with combination hose
nozzles to hose drops with suitable racks, reels or in boxes throughout all buildings.
Ensure the number and placement of hoses is such that all areas of the building
can be reached by at least one hose stream.
Ensure all equipment is of type, size and quantity as listed by a nationally

recognized testing laboratory.
Install hose reels in high piled warehousing and other catastrophic hazard areas so
that any point in the storage can be reached by two hose streams.
Roof Hose Connections
Provide and arrange fire hose connections and cabinets such that hose streams
can reach designated hazard areas of the roofs.
Ensure a sufficient amount of fire hose and combination nozzles are available for
use with the roof hose connections.
3.2 Special Extinguishing Systems
Design special extinguishing systems for a full discharge into the largest hazard
area. Design and install these systems in accordance with local codes and
manufacturers’ instructions.
4
Level
Ensure all components used in special extinguishing systems are listed and/or
approved for their intended purpose by a recognized testing laboratory.
3.3 Portable Fire Extinguishers
Place a sufficient number of portable fire extinguishers of the proper type and size
throughout all facilities. Distribute the units in accordance with local code
requirements.
3.4 Fire-Related Detection and Monitoring
Provide continuous monitoring of the following:
Water flow (both wet and dry pipe) for each sprinkler riser
Multiple story buildings must have a water flow device for each feed from the
main riser
Excess and low air pressure for dry pipe and pre-action systems
Manual fire alarm boxes
Post indicator, sectional control, OS&Y and indicator butterfly valves where
valves are exposed to the public
As an alternative to monitoring, valves may be locked open with hard shank
locks.
Fixed fire extinguishing equipment (gaseous systems, wet and dry chemical,
water spray, etc.)
Heat detection equipment (rate of rise, fixed temperature, etc.)
Smoke detection equipment (ionization, photoelectric, etc.)
Building temperature (critical areas or warehouses, truck centers or
training centers which do not have 24-hour security)
Electric fire pump

o Controller has operated into a motor running condition
o Loss of line power on line side of motor starter in any phase
o Phase reversed on line side of motor starter
5
Level
Diesel fire pump

o Engine running
o Controller main switch to "off" or "manual" position
o Trouble (common alarm to include the following):
o Low oil pressure
o High engine jacket coolant temperature
o Failure of engine to start automatically
o Shutdown from overspeed
o Battery failure
o Battery charger failure
Water storage reservoirs

o Low level and high level
o Low water temperature (minimum 40º F or 5º C)
Security intrusion devices

o Specific doors or gates as required
o Assistance required at medical, lobby or other critical areas
4.0 RECORDS – N/A
5.0 REFERENCES – N/A

Contact
7.0 DEFINITIONS
Highest Fire Challenge: The highest fire challenge is based on sprinkler demand,
including a 10% allowance for hydraulic imbalance, and simultaneous hose stream
demand.
Source: The actual origin of, or facility containing, the water supply, such as: a
lagoon, lake, reservoir or other body of water; a series of wells; city water system;
or a man-made facility such as an underground reservoir, ground level (suction)
tank, etc.
6
Level
Supply: The quantity of water of known volume, pressure and rate of flow
immediately available for fire automatic and manual fire suppression.
7
Level
8.0 APPENDIX
Material contained in this appendix provides additional detail and clarification of

the related standards. It contains explanatory material numbered to correspond
with the related standards contained in this chapter.
8.3.1.2 Fire Pumps
Consideration should be given to the proper distribution of electrical and diesel

drivers in the event of electrical power failure. Diesel engine drivers are
preferred due to the increased cost of the electrical supply arrangements
required to assure reliability. If there is only one fire pump serving the property, it
should be diesel driven.
8.3.1.3 Water Supply Distribution Piping
It is preferred, and may be necessary, that the underground water supply

distribution piping be looped around each major building. The following are
factors to consider when determining the appropriate underground piping
installation:
Looped piping provides distinct hydraulic advantages in meeting sprinkler

system demands, which may allow the use of smaller diameter pipe.
Looped piping provides water from two directions, resulting in greater

reliability.
Looped piping provides greater flexibility in hydrant placement.
8.3.1.4 Sprinkler Systems
For limited areas (20 sprinklers for ordinary hazard occupancies and 15
sprinklers for extra hazard occupancies) under obstructions such as platforms
and conveyor screen guards, sprinklers may be installed on a pipe schedule
basis. To ensure adequate protection, the point of connection for the above
sprinklers should be at least two pipe sizes larger than the pipe schedule.
The maximum base of riser pressure demand should not exceed 90 psi (6.1
bars). Additional hydraulic calculations to the discharge side of the pump(s) are
required to verify that the hose and sprinkler system water demands can be met.
1 Appendix
Level
Exceptions for higher base of riser pressure demand may be made on a case-by-
case basis if the facility has fire pumps in excess of 125 psi (8.6 bars) net rated
pressure. Also, excess of 90 psi (6.1 bars) is permitted if ESFR sprinkler
systems are employed.
Higher temperature rated sprinkler heads may be substituted for ordinary

temperature rated 165º F (74º C) heads in areas such as heat treat operations
and oven enclosures.
8.3.1.5 Hose Systems
Interior Fire Hose
Hose outlets should utilize the same thread standard as the local fire service. In
situations where different thread standards exist, adapters should be available.
Roof Hose Connections
Examples of designated hazard areas on roofs include paint shops, heat treat
areas, oven enclosures, combustible cooling towers, and dust collectors.
It is preferred that hose be kept in the roof hose cabinets, pre-connected to the
water supply. However, it is acceptable to have hose packs available at nearby
roof entrances.
All equipment should be of a type, size and quantity as listed by a nationally

recognized testing laboratory.
Hose outlets should utilize the same thread standard as the local fire service. In
situations where different thread standards exist, adapters should be available.
8.3.2 Special Extinguishing Systems
Special extinguishing systems generally include fixed fire protection other than
automatic sprinkler systems. Specific examples are local application or total
flooding gaseous, wet or dry chemical, foam and water spray systems.
8.3.3 Portable Fire Extinguishers
Extinguishers should be installed in accordance with NFPA 10 - Portable Fire

Extinguishers, or the equivalent local code or ordinance.
2 Appendix
Level
8.3.4 Fire-Related Detection and Monitoring
The preferred method of monitoring is a protective signaling system under

constant supervision in a central supervising station at each facility complex. For
small warehouses, truck centers, training center locations, etc., the use of a
central station system is satisfactory.
Where an adequate protective signaling system cannot be provided, monitoring

can be achieved with a combination of the following:
A local alarm for each device for which monitoring is required
An adequate number of personnel, located such that any local alarm can
be readily detected and investigated, and proper response initiated
In addition to those items listed in the standard, the following are recommended:
A water flow device on each auxiliary system (dry-pipe, deluge, pre-

action).
Electronically monitored patrol tours
As an alternative, patrols can be recorded by a stand-alone listed

recording system.
Monitoring of all valves on new construction or new proprietary systems
3 Appendix
Fire Prevention & Protection - Chapter 6
Fire Alarm System Standard
Author Technical Revision Approver Name Effective Date
Contact Level
1.0 PURPOSE
This chapter provides standards and additional information with regard to fire
alarm systems and equipment.
2.0 SCOPE

3.0 STANDARDS
Install and maintain a fire alarm system to provide detection of a fire or other
emergency conditions and initiate occupant notification appliances.
Follow GM Worldwide Facilities and Information Technology standards and

specifications for installation of fire alarm systems.
The system should be equipped to provide reliable continuous service including

adequate power sources with addressable supervised circuits. Do not use the
system for other than the intended purpose.
Use factory certified personnel to install and maintain the system.
3.1 Functional Requirements
An initiating device must activate a signal to a fire alarm control unit. The fire
alarm control unit must indicate, alphanumerically, the specific information about
the signal including the type of signal (alarm, trouble, reset), device type and
exact device location.
Monitor the system for events using a constantly attended monitoring station.
Use a notification system to alert occupants of a fire, evacuation, or take shelter

emergency. Notification signals must be distinguishable from other systems
within a building. Use a fire alarm control unit to automatically activate the
emergency notification system. Ensure occupant notification systems produce
distinct and unique visual or audible signals for the following:
Evacuation
Take Shelter
All Clear
Contact Level
3.2 System
A complete fire alarm system consists of initiating devices, fire alarm control
units, and notification appliances. Connect all fire alarm control units to create a
single networked system per building or group of buildings. Control the entire fire
alarm system with a single head end control unit.
3.2.1 Fire Alarm Control Units
Use a fire alarm control unit that is approved by an independent authority or

testing laboratory. Ensure the control unit is capable of receiving and
annunciating or retransmitting alarm signals. Ensure the operator of the system
can perform the following functions:
Acknowledge
Silence
Reset
Bypass an initiating device or multiple devices
Identify current device status
System test
Voice notification
3.2.2 Initiating Devices
Locate initiating devices as required by code or where necessary to minimize

risk. Initiating devices include manual pull station alarms, smoke detectors,
water flow switches, critical equipment monitoring and all other devices that
trigger a signal to the fire alarm control unit.
3.2.3 Notification Appliances
Notification appliances include devices such as horns, speakers and strobes.

Use these devices to alert occupants of the building in the event of a fire,
evacuation, take shelter emergency, system testing, or all clear. Locate and
maintain devices to provide notification to all occupants throughout the entire
premises. Non life safety usage of the system (i.e., shift break tones) must not
interfere with the emergency notification messages. Emergency notification must
take priority over any other use of the system.
Contact Level
3.3 Monitoring Station
Monitoring of the system may be performed by a central monitoring service, a

proprietary system, or a combination of both. Ensure the monitoring station will
receive the signal from the fire alarm system including the type of signal (alarm,
trouble, reset), device type and exact device location.
3.2.1 Central Monitoring Service (Only)
The facility may subscribe to a service providing remote alarm monitoring. This
service may supplement a locally monitored system. Use a service that is
approved by an independent authority or testing laboratory.
3.2.2 Proprietary System Monitoring (Only)
Establish a proprietary supervising station within the protected premises.

Provide 24 hours a day, 365 days a year staffing of the supervising station.
Ensure the supervising station is equipped with:
Communication equipment such as a telephone in order to notify
emergency services.
Provide 24 hours of stand-by power in order to maintain a constant
operating environment.
Physical barriers or access control to restrict access to trained operators
and service personnel.
A software application designed to provide a user interface to manage
and monitor the complete system. The application must be approved for
use by the manufacturer of the installed fire alarm system.
An event printer
3.2.3 Central Monitoring Service and Proprietary System (Combination)
The facility may subscribe to a service providing a central monitoring station and
also monitor the proprietary system locally as needed. In addition to the central
monitoring service requirements above (section 3.3.1), provide local staff with a
software application designed to provide a user interface to manage and monitor
the complete system. The proprietary system does not need to be constantly
attended when combined with a central monitoring service.
Contact Level
3.4 System Inspection and Maintenance
Establish a process to conduct regular system testing. Conduct inspections of

the system using factory certified personnel. Conduct inspections annually and/or
as required by code. Perform inspections based on the manufacturer’s minimum
requirements.
Establish a process to report system impairments and track them to resolution.
Establish a process to have factory certified service personnel available to make

system repairs.
4.0 RECORDS
Record the results of a complete system test and inspection annually or more
frequently as required by local regulations.
Record the system impairments and steps taken to resolve them.
Maintain system event history, impairments, test, and inspection records

according to General Motors information life cycle management requirements.
5.0 REFERENCES
This standard references the following standards, documents or guidelines:

NFPA 72, National Fire Alarm and Signaling Code, 2010 Edition

10/05/2010 1.0 Standard created.
7.0 DEFINITIONS
Fire Alarm Control Unit

A component of the fire alarm system, provided with primary and secondary
power sources, which receives signals from initiating devices or other fire alarm
control units, and processes these signals to determine part or all of the required
fire alarm system output function(s).
Contact Level
Fire Alarm System

A system or portion of a combination system that consists of components and
circuits arranged to monitor and annunciate the status of fire alarm or supervisory
signal-initiating devices and to initiate the appropriate response to those signals.
Head End
A control unit which sends and receives signals from the other control units on
the system network.
Initiating Device
A system component that originates transmission of a change-of-state condition,
such as in a smoke detector, manual fire alarm box, or supervisory switch.
Notification Appliance
A fire alarm system component such as a bell, horn, speaker, light, or text display
that provides audible, tactile, or visible outputs, or any combination thereof.
Notification System
A system for the protection of life by indicating the existence of an emergency
situation and communicating information necessary to facilitate an appropriate
response and action.
Proprietary System
A supervising station under the same ownership as the protected premises fire
alarm system(s) that it supervises (monitors) and to which alarm, supervisory, or
trouble signals are received and where personnel are in attendance at all times
to supervise operation and investigate signals.
8.0 APPENDIX
Fire Alarm Control Units
Locate a voice communication panel at the proprietary supervising station when

using a voice occupant notification system. Equip the panel with a microphone
and a changeable message player to announce test and evacuation messages.
Use control switches for the following:
Manual audio evacuation (all areas)
Selective manual audio evacuation
Talk to all speaker/all call
Take shelter warning (may include separate severe weather warning)
All clear
Contact Level
Design the system to provide clear intelligible messages to the entire occupied
premises. Use the voice communication system for the intended purpose only.
Non life safety usage of the system (i.e., shift break tones) must not hinder
emergency notification messages. Emergency notification must take priority over
any other use of the system.

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Fire Prevention and Protection Section

Chapter 1- Safe Work Environment

This chapter provides standards and additional information to assist GM leaders

The following standards relate to providing fire prevention and emergency

3.1 Emergency Egress

Conduct periodic inspections of emergency egress components as outlined in the

Arrange aisles to provide a continuous egress path. Aisles must be sufficiently

Provide adequately identified, clearly visible and accessible means of egress in

Do not store materials in stairwells.

Provide adequate emergency lighting in the event of power failure.

3.1.5 Egress Planning Requirements

Establish an evacuation procedure for each facility.

Post evacuation diagrams in appropriate locations within the facility.

For non-manufacturing buildings, such as offices and engineering centers, with

Complete and document a Low-Rise Life Safety Evaluation Survey annually.

3.2. Emergency Notification Systems

Ensure emergency notification signals are distinguishable from other signaling

Ensure occupant notification systems are capable of producing distinct visual

These audible signals should be tested on an annual frequency.

3.3 Emergency Response Planning

3.3.1 Emergency Response Coordinating Team Organization

Establish an Emergency Response Coordinating Team (ERCT) to ensure

3.3.2 Emergency Response Plans

An Emergency Response Plan (ERP) must be developed and maintained by the

3.3.4 Emergency Reporting

3.4 Welding & Cutting (Hot Work) Operations

3.4.1 Permit System Requirements

Prior to the performance of any welding, cutting, grinding or allied processes, a

The inspection must include specifying the appropriate fire extinguishing

The permit must be denied if:

The area contains fire hazards which cannot be eliminated

3.5 Fire Protection Impairment Management

Develop a written program for reporting, monitoring, and managing impairments of

Manage impairments to fire protection systems and equipment in accordance with

3.6 Fire Protection Equipment Inspection

3.6.1 Required Inspections

3.6.1.1 Fire Barrier Partitions and Fire Walls

3.6.1.2 Heat and Smoke Vents

3.6.1.3 Water Supply Facilities

Conduct a routine maintenance inspection of the water supply facilities. Maintain

3.6.1.4 Fire Pumps

3.6.1.5 Fire Protection Mains and Hydrants

3.6.1.6 Fire Protection System Valves

3.6.1.7 Automatic Sprinkler Systems

Inspect dry pipe valve enclosures at least daily (weekly if temperature is

3.6.1.8 Exterior/Interior Fire Hose and Roof Hose Cabinets

3.6.1.9 Emergency Lighting

Inspect emergency lighting facilities monthly. Battery trickle charge units’

Start emergency generators on a monthly basis.

3.6.1.10 Proprietary Alarm System

3.6.1.11 Fire Trucks

3.6.1.12 Portable Fire Extinguishers

Perform a visual inspection monthly to ensure portable extinguishers are available

Perform maintenance on each extinguisher annually and when indicated by an

3.6.1.13 Ovens and Furnaces

Perform functional testing of combustion safety controls for fuel-fired equipment

Establish a regular inspection of drying ovens to ensure combustible residues are

Prohibit smoking in locations containing a potential fire or explosion hazard.

3.9 Fire Response

3.9.1 Personnel Evacuation

Emergency response planning must include development of an evacuation plan for

3.9.2 Alarm Response

Every fire-related alarm must be investigated by Security or by management for