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The use of fire retardants is a requirement to reduce fire severity and deaths but is also controversial due to environmental (leaching) and health consequences of commonly used halogenated fire retardants. A novel methodology has been developed and validated in the Fire Safety Engineering Research and Technology centre (FireSERT), Built Environment Research Institute, for the prediction of large-scale burning behaviour of fire retarded polymers by combining small-scale (mg size) experiments with computer simulations of fire growth and toxicity. The research has been instrumental for companies in redesigning their products (fire doors and intumescent coatings) and is informing the development of EU regulations regarding the use and replacement of halogenated fire retardants. The research output has been published in leading journals, cited widely internationally and referenced by key organisations.
Our research provided the evidence to persuade companies to develop fire retardant formulations based on naturally occurring mixtures of hydromagnesite and huntite (HMH) that were more effective, cheaper, and greener than the market leader, aluminium hydroxide (ATH). Before the research started, in 2005, annual global sales of HMH as a fire retardant were less than [TEXT REMOVED FOR PUBLICATION] 000 tonnes. By 2012, sales had already doubled to [TEXT REMOVED FOR PUBLICATION] 000 tonnes (£[TEXT REMOVED FOR PUBLICATION] M) and continue to grow. LKAB minerals supply over 90% of the global market in HMH, and as a result of UCLan's fire retardant research, expect HMH to replace at least 25% of fine grade ATH within 5 years (increasing HMH sales to £[TEXT REMOVED FOR PUBLICATION] M). Not only is HMH a more effective fire retardant, it does not have the environmental problems associated with ATH.
The Steady State Tube Furnace (ISO/FDIS 19700) allows fire toxicity to be quantified in real fire conditions. This has led to the introduction of "acidity classification" for cables in the European Construction Products Directive/Regulation (2008/2013) (as a surrogate for fire toxicity) to promote the use of safer, low smoke, zero halogen (LSZH) alternatives to PVC cables. Additionally, architects and building specifiers can use our data to avoid the most toxic foam insulation materials in low energy buildings. The biggest impact of our work, the global reduction in loss of life in fire is probably the most difficult to quantify, as too many other factors influence the fire statistics.
Enhanced public safety and transformation of structural design for fire has resulted from improved building design through ERPE researchers' development of new and unique design methodologies, frameworks and tools for analysing fire spread. Fire safety engineering research within ERPE has created an improved scientific understanding of the effect of fire on structures and materials. Structural and fire safety engineers across UK, EU, USA, Canada as well as those who are members of international fire safety bodies have subsequently implemented significant advances for the design of safer, more economical, sustainable, and architecturally innovative buildings.
ERPE research has thus assisted the design and construction of increasingly optimised, sustainable, and economical buildings globally with significant changes in building design and regulation, particularly during 2009-2013.
This case study is about the development of flame retardant (FR) polypropylene yarns used in upholstery fabrics for domestic and office furniture, automotive and floor coverings that will have predictable and reproducible fire retardant properties when subjected to standard testing procedures. Through the UK DTI funded project FLAMTECH (2002-2005) shared by Camira Fabrics Ltd., and the university, a range of novel polypropylene yarns having higher levels of consistent fire performance than the previously existing products in the market place were developed. A testing protocol which could establish individual fibre/yarn/fabric structural-fire property relationships and correlate these with (and hence predict) final fabric performance was also established. The project overlapped a concurrent EPSRC funded research in which nanocomposite fibres (including polypropylene) with improved flame retardancy and reduced melt dripping were developed. Camira were also members of the consortium managing this project. The major commercial outcome from these projects since 2005 is a flame retardant polypropylene product being marketed by Camira fabrics within their Perfentex brand and others are also being considered. This work also inspired the Production Director of Camira Fabrics to register at Bolton as a PhD-by-publication candidate and hence gain more knowledge about the subject area, as evidenced by the publication of her research papers (see Paper 1, Section 3).
The development of standards and design guides at a European level for composite concrete floors with cellular steel beams has been informed by research undertaken in the Fire Safety Engineering Research and Technology centre (FireSERT), Built Environment Research Institute. Central to the impact is the establishment of technical rules for the fire safe design of buildings constructed with the use of cellular beams. Research at the University of Ulster has demonstrated that the use of unprotected cellular beams can reduce the cost of fire protection. This research was corroborated by a major fire test conducted at an international scientific conference hosted by FireSERT in February 2010. Design guidance for innovative safe structures in fire scenarios have been published in leading journals with high impact factors.
Impact on industry, academia and government institutions from engineering materials research in the Mechanical Engineering department has been delivered through it directly leading to UK, USA and International Standards and Codes relating to three themes:
The results of the research of staff in this unit have led directly to UK, US and International Standards and Codes: ASTM Standards E1457-07 (2012) and E2760-10 (2012); R5 EDF Energy Code of Practice (2012); BS 7910 (2013); ISO 25217 (2009); ISO CD 15114 (2011) and ISO 13477 (2008). These documents all cite peer-reviewed publications by staff from this unit. These Standards and Codes are now the basis of fracture-mechanics methodologies used by leading engineering companies like Airbus, EDF, E.ON, GKN, Rolls-Royce and Vestas, whose commercial success depends upon technological leadership. In this way our research has led to savings by UK industry of many millions of pounds, as detailed in Section 4.
A manufacturing process developed by Bradford researchers has revolutionised the way endodontists perform root canal treatments. When coated with a hydrophilic polymer, the highly-filled hygroscopic material has enabled UK company DRFP to develop SmartPoint — a new endodontic technique that dramatically reduces failure rates of root canal treatments from 11-30% over five years to approximately 1%, and gives lower levels of post-operative pain when compared with conventional techniques. The technology has won three awards for innovation and DRFP has expanded significantly, with a dedicated production facility and sales team offering visits to dentists to demonstrate the benefits of the technology.
Initial research into polymer nanocomposites and their formation took place at Strathclyde from 2000 - 2010. This was followed by a collaboration with the world's largest manufacturer of composite kitchen sinks, Carron Phoenix Limited, through a 6-year Knowledge Transfer Partnership (KTP) which resulted in a successful new production process of its high-end synthetic granite kitchen sinks. This led to £4 million of capital investment in new production facilities at their Falkirk site, enabling the company to sustain its leading position in the designer kitchen sink market and retain its workforce of over 400 employees in central Scotland, including the 170 workers in the composite sink division in Falkirk. Within the REF period, the research has led to the manufacture and sale of in excess of one million kitchen sinks, generating sales revenue in excess of over £50M and supporting the UK economy.
Research into variable mechanical energy absorption, using Finite Element (FE) modelling and analysis, funded by Cellbond Ltd., led to a design specification for an Offset Deformable Barrier (ODB). Such barriers are used within the motor manufacturing industry to test vehicular safety. Based on the findings of our research, the barrier used in car crash tests has been redesigned. The design specification for the barrier has been adopted by the European New Car Assessment Programme (EuroNCAP). All newly designed cars are tested with this type of barrier before they enter production. The use of FE modelling and virtual crash testing allows barriers to be designed with particular properties and for the crash testing cycle to be shortened.