NFPA 285 Testing for Exterior Walls

Requirements and Design Challenges

Brian D. Kuhn, Jr., P.E.

28 November 2011

www.sgh.com

Simpson Gumpertz & Heger Inc. is a Registered Provider with The

American Institute of Architects Continuing Education Systems (AIA/CES).
Credit(s) earned on completion of this program will be reported to
AIA/CES for AIA members. Certificates of Completion for both AIA
members and non-AIA members are available upon request.

This program is registered with AIA/CES for continuing professional

education. As such, it does not include content that may be deemed
or construed to be an approval or endorsement by the AIA of any
material of construction or any method or manner of handling, using,
distributing, or dealing in any material or product.

Questions related to specific materials, methods, and services will be

addressed at the conclusion of this presentation.

28 November 2011 NFPA 285 Testing for Exterior Walls 2

 Copyright Materials
This presentation is protected by US and
International Copyright laws. Reproduction,
distribution, display and use of the presentation
without written permission of the speaker is
prohibited.

© Simpson Gumpertz & Heger Inc. 2011

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Course Description

The presentation addresses fire testing requirements for combustible

exterior wall materials as found in the International Building
Code. There is currently a lack of consistent interpretation and
enforcement of such requirements among designers and code
enforcement bodies. This presentation will summarize the language of
the building code as it relates to fire test requirements for exterior walls,
the nature of the referenced test standards, and the application of
tested assemblies in typical wall design.

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 Learning Objectives

• Identify exterior wall materials and systems that require

fire propagation testing.
• Distinguish between the NFPA 285 test and alternate
test methods.
• Interpret product literature and reports of tested wall
components and assemblies.
• Incorporate compliant materials and systems into
exterior wall design.

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Simpson Gumpertz & Heger

• Structural Engineering
• Building Science &
Technology
• Materials Science
• Fire Safety Engineering
• Laboratory

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 Exterior Wall Fundamentals

BARRIER 1: Rainwater/Groundwater
Waterproofing Control

BARRIER 2:
Insulation

Condensation
BARRIER 3: Control
Vapor Retarder &
Energy Consumption

BARRIER 4:
BUILDING SCIENCE
Air Barrier

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Exterior Wall Fundamentals

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 Presentation Overview

• How the Code Reads

– Requirements for Combustible Materials in Walls
– The NFPA 285 Test Standard
– Special Approval language
• What’s Happening in Practice
– Design Challenges in Working with NFPA 285
– Issues with Currently Approved Assemblies
– A Look at the NIBS RFP
• Where We Need to Go

**All code references in accordance with 2009 IBC. Codes vary by jurisdiction;
requirements for individual projects should always be verified on a case-by-case basis.**

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Code Requirements

• A building shall be classified as one of five types of

construction (IBC Chapter 6)

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 Code Requirements

• Combustible materials

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Code Requirements

Combustible materials are permitted in non-combustible

construction (Section 603):
• Combustible exterior wall coverings in accordance with
Chapter 14
– Exterior Insulation and Finish Systems (EIFS)
– Metal Composite Materials (MCM)
– High-Pressure Laminates (HPL) (2012 IBC)
• Plastics in accordance with Chapter 26
– Fiber Reinforced Polymers
– Foam Plastic Insulation
• Exterior plastic veneer in accordance with Section
2605.2

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 Code Requirements

• Side note on plastic veneer (think: vinyl siding)

– Not subject to NFPA 285 testing
– Can’t be used higher than 50 feet above grade
– Has requirements for self-ignition temperature, smoke-developed
index, and combustibility classification

• Side note on water-resistive barriers (2012 IBC)

– NFPA 285 testing will be required for all exterior wall systems
greater than 40 feet in height that include a combustible water-
resistive barrier

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Code Requirements

Metal Composite Materials (Section 1407)

• Definitions:
– MCM: Factory-manufactured panel consisting of metal skins
bonded to both faces of a plastic core (foam plastic exempted)
– MCM System: Exterior wall covering fabricated using MCM in a
specific assembly including joints, seams, attachments, substrate,
framing, and other details as appropriate to a particular design

Alpolic PE

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 Code Requirements

Metal Composite Materials (Section 1407)

• Fire safety requirements:
– Fire-resistance rating of wall maintained (ASTM E 119)
– Surface-burning characteristics (Class B) (ASTM E 84)
– Full-scale NFPA 285 testing, or comply with alternate
conditions

Alpolic PE

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Code Requirements

Metal Composite Materials (Section 1407)

• Option 1: Unlimited height
– NFPA 285 testing and Class A rating
• Option 2: Installations up to 40 feet
– Unlimited surface coverage, unless fire separation distance
less than 5 feet (10% coverage limit)
• Option 3: Installations up to 50 feet
– Self-ignition temperature of 650F or greater
– Sections of MCM shall not exceed 300 sf, and shall be
separated at least 4 feet vertically

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 Code Requirements

Metal Composite Materials (Section 1407) (2012 IBC)

• Option 4: Installations up to 75 feet
– Self-ignition temperature of 650F or greater
– Area limitations
– Prohibited occupancies (A-1, A-2, H, I-2, I-3)
– Limited to non fire-resistance rated walls
– Exceptions for automatic sprinkler systems
• Option 4a: Installations up to 75 feet
– Self-ignition temperature of 650F or greater
– Area limitations
– Fire separation distance must be greater than 30 ft
– Exceptions for automatic sprinkler systems

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Code Requirements

Metal Composite Materials (Section 1407)

• Full Scale Tests. The MCM system shall be tested in
accordance with, and comply with, the acceptance
criteria of NFPA 285. Such testing shall be performed
on the MCM system with the MCM in the maximum
thickness intended for use.

• MCM System: Exterior wall covering fabricated using

MCM in a specific assembly including joints, seams,
attachments, substrate, framing, and other details as
appropriate to a particular design

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 Code Requirements

Plastics (Chapter 26)

• Fiber Reinforced Polymers (FRP)
• Foam Plastic Insulation (FPI)
– Exterior Finish and Insulation Systems (EIFS)
• Expanded polystyrene (EPS)
– Rigid insulation
• Polystyrene (XPS)
• Polyisocyanurate (ISO)
– Spray polyurethane (SPUF)

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Code Requirements

Fiber Reinforced Polymers (Section 2612)

• Option 1a: Unlimited height
– NFPA 285 testing
• Option 1b: Unlimited height
– Class A rating – up to 20% coverage
– Class B rating – up to 10% coverage
– Applied to, or separated by, a noncombustible substrate
• Option 2: Installations up to 40 feet
– Unlimited surface coverage, unless fire separation distance less
than 5 feet (10% coverage limit)
– Class C rating

NOTE: All options require fireblocking

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 Code Requirements

Section 2603.5. Exterior walls of Types I, II, III, IV

construction greater than one story*.
1. FPI can’t decrease the fire-resistance rating
2. Thermal barrier must separate FPI from building interior
3. Limited potential heat of FPI
4. Class A rating
5. The wall assembly shall be tested in accordance with
and comply with the acceptance criteria of NFPA 285
6. Proper labeling required
7. Must past ignition resistance test

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Code Requirements

Section 2603.9 Special approval

• FPI is not required to comply with 2603.4 through 2603.7
where approved based on large-scale tests
– NFPA 286 and UL 1715: Standard Room Corner Tests
– FM 4880 and UL 1040: Large-scale Room Corner Tests

• “Such testing shall be related to the actual end-use

configuration…assemblies tested shall include seams,
joints and other typical details used in the installation of
the assembly…”

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 The NFPA 285 Test

• Original full-scale version was first codified in 1988

Uniform Building Code (UBC) as Test Standard 17-6
• Society of Plastics Industry (SPI) testing in early 1990s
led to the intermediate-scale UBC 26-9 in 1997 UBC
• NFPA adopted NFPA 285 in 1998 based on UBC 26-9
• Each IBC edition has referenced NFPA 285

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The NFPA 285 Test

• Application. Standard used to evaluate fire

propagation characteristics of wall assemblies, as
follows:
– Vertical flame propagation:
• over the exterior face of the wall assembly
• within the combustible core or within combustible
components from one story to the next
• over the interior surface of the wall assembly from one
story to the next.
– Lateral flame propagation from the compartment of
fire origin to adjacent compartments or spaces.

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 The NFPA 285 Test

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The NFPA 285 Test

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 The NFPA 285 Test

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The NFPA 285 Test

• Testing Laboratories
– Intertek (San Antonio, TX)
– Southwest Research (San Antonio, TX)
– Architectural Testing (York, PA) (coming Spring 2012)
• Cost
– $15,000 to $20,000
• Timeframe
– 6 to 10 weeks

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 Special Approval

Section 2603.9 Special approval

• FPI is not required to comply with 2603.4 through 2603.7
where approved based on large-scale tests
– NFPA 286 and UL 1715: Standard Room Corner Tests
– FM 4880 and UL 1040: Large-scale Room Corner Tests

• “Such testing shall be related to the actual end-use

configuration…assemblies tested shall include seams,
joints and other typical details used in the installation of
the assembly…”

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Special Approval

• NFPA 286, UL 1715: Standard room corner test

• Pass/fail based on flame spread, heat released, smoke
generated, flashover

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 Special Approval

• FM 4880 –
Large-scale
room corner test

Photograph courtesy of
FM Approvals

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Special Approval
Photograph courtesy of
FM Approvals

28 November 2011 NFPA 285 Testing for Exterior Walls 32

 Special Approval
Photograph courtesy of
FM Approvals

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Special Approval

Section 2603.10.1 Exterior Walls (2012 IBC)

• Testing based on Section 2603.10 shall not be used to
eliminate any component of the construction of an
exterior wall assembly when that component was
included in the construction that has met the
requirements of Section 2603.5.5.

28 November 2011 NFPA 285 Testing for Exterior Walls 34

 Design Challenges

#1 Special approval section is unclear (2012 IBC language

doesn’t help)
#2 Lack of a central directory of NFPA 285-approved
assemblies
#3 Unclear path for modifying tested assemblies
#4 Typical wall designs include components or details that
are not consistent with tested assemblies

28 November 2011 NFPA 285 Testing for Exterior Walls 35

Design Challenges

Challenge #1
• Special approval section is unclear
• Why is the requirement for exterior wall fire testing
waived by an interior finish test?
• Various interpretations on the subject

28 November 2011 NFPA 285 Testing for Exterior Walls 36

 Design Challenges

Challenge #2
• Lack of a central directory
• For other fire-resistive assemblies, the industry reference
is Underwriters Laboratories’ Fire Resistance Directory

• For assemblies tested to NFPA 285, there is no such

compilation of approved assemblies

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Design Challenges

• Foam Sheathing Coalition memo – 26 Oct 2010

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 Design Challenges

• International Code Council (ICC) Engineering Service

(ES) reports are not always clear

• Two examples:
– Standard EIFS by Parex
– STYROFOAM rigid insulation by Dow

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Design Challenges

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 Design Challenges

28 November 2011 NFPA 285 Testing for Exterior Walls 41

Design Challenges

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 Design Challenges

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Design Challenges

• To gain understanding of all details of the tested

assembly, the designer needs to correspond with the
sponsor of the test.
• For an assembly test with multiple components and
manufacturers, who sponsors the test?
• So far, it has been the insulation manufacturers

28 November 2011 NFPA 285 Testing for Exterior Walls 44

 Design Challenges

28 November 2011 NFPA 285 Testing for Exterior Walls 45

Design Challenges

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 Design Challenges

28 November 2011 NFPA 285 Testing for Exterior Walls 47

Design Challenges

Challenge #3
• Mechanism for substitution of components
– Size of air space
– Type of water-resistive barrier
– Other details
• ES Acceptance Criteria (AC) 12 allows for extension of
test data through engineering analysis
• Equivalency required for project?

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 Design Challenges

Challenge #4
• Common wall designs include components or details that
are not consistent with tested assemblies
– Lack of approved asphalt-based membranes in field of wall

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Design Challenges

Challenge #4
• Common wall designs include components or details that
are not consistent with tested assemblies
– Lack of approved asphalt-based membranes in field of wall

• Will be further complicated by 2012 IBC language

– NFPA 285 testing required for all exterior wall systems greater
than 40 feet in height that include a combustible water-resistive
barrier

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 Design Challenges

Challenge #4
• Common wall designs include components or details that
are not consistent with tested assemblies
– Required fire safing at window openings

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Design Challenges

• Aesthetic concerns
• Water collection and
drainage concerns
• Thermal bridge
• Flashing??

Detail from Dow literature

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 Design Challenges
Detail from
Owens Corning
literature

Continuous Steel Lintel/Shelf Angle on Steel Framing

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Design Challenges

Challenge #4
• Common wall designs include components or details that
are not consistent with tested assemblies
– MCM Systems have not passed NFPA 285 with XPS insulation

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 Where Do We Go From Here?

• Common systems may

not meet letter of the
code

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Where Do We Go From Here?

• National Institute of Building Sciences (NIBS) –

Request for Proposal to evaluate IBC requirements and
NFPA 285 test standard

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 Where Do We Go From Here?

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Design Alternatives
• Use existing NFPA 285 tested
system, possibly modified
with engineering judgment
• Jurisdiction-specific solutions
• Test new system
• Switch to a non-combustible
insulation (mineral wool)

28 November 2011 NFPA 285 Testing for Exterior Walls 58

 Where Do We Go From Here?
Mineral wool insulation
• Lower R-value than XPS
– Larger cavity space
– Wider horizontal relieving
angles
• Thermal performance when
wet
• Track record?

• Recycled content can be

used toward LEED credits
• Still use asphalt-based
WRBs

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Where Do We Go From Here?

Weather-resistive barriers
• Manufacturers are
developing impermeable
self-adhered membranes
for compliance with NFPA
285

28 November 2011 NFPA 285 Testing for Exterior Walls 60

 Where Do We Go From Here?

NFPA 285 Directory

• Underwriters Laboratories?
• NFPA?
• Foam Plastics Industry?

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Where Do We Go From Here?

Communication with Stakeholders

• Design Team
• Owner
• Authority Having Jurisdiction
(AHJ)

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Thank You

Brian D. Kuhn, Jr., P.E.

bdkuhn@sgh.com
(781) 907-9328

www.sgh.com