FIRESHIELD
Regina FireShield is a ground-breaking material, endowing composites with high fire resistant properties. It can be used normally in most manufacturing techniques, including pultrusion, filament winding, liquid moulding, LFI etc.
Initially developed for an aerospace application by the Composites CRC, this product is now ready for general use by the Composites Industry. Mass Transit provides particularly suitable applications.
The Regina Fireshield product works by:
• producing a well-bonded, charred layer on the surface of the product, under the action of a fire/flame. This bonded char layer insulates the product and inhibits the passage of oxygen, thereby smothering the flame;
• placing low smoke intumescent chemical at the surface of composite parts, avoiding the environmental problems of halogenated systems;
• avoiding loss of strength inherent when filling the base resins with intumescent chemicals, permitting smaller, lighter weight sections;
• Replacing hazardous phenolic resin manufacturing processes i.e. cured phenolic itself is not hazardous, but chemicals involved (e.g. formaldehide) are hazardous.
FireShield usually uses glass surface tissue as a carrier to place the halogen-free, fire retardant chemical just beneath the surface of composite parts. Although non-woven glass tissue provides the least-cost method for applying this technology, other fibres such as polyester or carbon, can be used as carriers, both in non-woven and woven form, to meet particular engineering requirements.
Note that FireShield is resin specific, and orders for the product should nominate the resin type with which it will be used.
STANDARDS
Aerospace international standards for flame (FAR25.853(a)), smoke and toxic gas emission (ABD0031; ASTM-E662), have been met by products using this technology. Standards in maritime, and ground transportation, areas traditionally challenging for composite material use, are equally expected to be met. Details of tests carried out so far are given HERE
MANUFACTURING WITH FIRESHIELD
To achieve fire protection integrity, any possible penetrations of the FireShield layer during later assembly need to be considered. Likewise edges of panels may need to be protected.
Manufacturing Instructions for particular composite manufacturing techniques are provided HERE.
If your process is not covered, please contact us for advice.
FireShield Manufacturing Instructions:
The Regina FireShield product:
• Enables your composite product to achieve industry standard fire specifications by simply placing a layer of FireShield at the outer surface;
• Avoids the environmental problems of halogenated systems through the use of low smoke intumescent chemical;
• Under the action of a fire or flame, produces a well-bonded, charred layer on the surface of the product. This bonded char layer insulates the product and inhibits the passage of oxygen, thereby smothering the flame;
• Avoids loss of strength by not filling the base resins with fire retardant chemicals, permitting smaller, lighter weight sections;
• Can replace hazardous, phenolic resins, whilst maintaining a high fire rating.
General Things to know about FireShield:
• Optimum performance of FireShield is achieved when it is placed as the outermost layer of the laminate, closest to the heat loaded region.
• Industrial grade epoxy, polyester and vinyl ester resin systems are compatible with FireShield
• FireShield may be used in standard composite manufacturing processes. These include hand lay-up, vacuum bagging, Vacuum Bag Resin Infusion (VBRI), RTM Lite, RTM, pultrusion and autoclave (prepreg) processes
• FireShield is NOT applicable to the Dough Moulding Compound (DMC) manufacturing processes
• FireShield is to be treated in the same manner as a reinforcement ply located on one or both outermost surfaces of the laminate. FireShield may also be used to encapsulate the entire surface of the composite
• Fire, smoke and toxicity screening tests should be performed in accordance with test specifications for the application requirement. Usually, the test specimen thickness is to be no thicker than the minimum thickness for the application. (Various fire screening tests are available through Regina Glass Fibre Pty Ltd.)
• Any cosmetic coating (paints, adhesives, resins, etc) applied after fabrication will hinder the performance of FireShield. If the finished part is to have a cosmetic coating of any kind, the specimen must be subjected to screening tests in the as-finished condition to confirm whether the part meets the specification requirements
• FireShield materials should always be stored in sealed polyethylene bags to reduce damage, contamination of surrounding chemicals and moisture absorption. FireShield left out of the protective pack may pick up moisture, causing blisters in the final product.
• Only one ply of FireShield is necessary to protect the region requiring fire protection. Multiple layers of FireShield should not be applied sequentially in the part lay-up
• In regions where two or more plies of FireShield meet due to geometry constraints, a minimum overlap of 1 mm must be maintained. It is crucial that all surfaces requiring fire protection are covered with FireShield. If for some reason there are regions that cannot be physically covered with FireShield, an intumescent coating must be applied after the part is fabricated. See final Section of this document for intumescent paints available on the market.
Manufacturing Process Methods:
Post Production Process
POST PRODUCTION PRACTICES:
Surface or Through-Thickness Intrusions
If the laminate surface is damaged or holes are drilled through the thickness such that resin/fibres are exposed, an intumescent coating/paint must be applied over that region to protect the exposed resin/fibre.
The following intumescent coating suppliers have products that have been tested successfully with FireShield. Review the technical data sheets and MSDS from the suppliers for procedures on how to use these coatings.
The two tested intumescent coatings are:
Firefree 88
Distributor:
Firefree Systems Australasia Pty Ltd
3 Beeston Street
Macgregor, ACT 2615, Australia
Tel: 02 6255 2437
Email: infoaus@firefree.com
NoFire
Distributor:
NQ Fire Protection Pty Ltd
3 Scott Street
Cairns, QLD 4870, Australia
Tel: 1 300 666 447
Email: nofire@nqfire.com
FireShield Manufacturer / Supplier & Technical Support:
21 Regina Street, Ballarat, Victoria 3350, Australia
Tel: +61 (0)3 5339 2214, Fax: +61 (0)3 5338 1013
Contact: Arthur Rendell; Email: arthurp@mpx.com.au
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Sheet Moulding Compound:
To ensure correct usage of FireShield during the SMC process, the following are recommended:
• Wear powder-free gloves while handling FireShield.
• DO NOT dispose of non-laminated FireShield in any waste-stream. Return all off-cuts of FireShield to Regina Glass Fibre Pty Ltd (address located below) for recycling. Laminated FireShield may be disposed of per in-house waste stream practices for consolidated parts.
• Before implementing FireShield into a production environment, it is highly recommended that specimens / prototypes are fabricated to refine production parameters.
• The FireShield material should be on a woven fibreglass cloth carrier.
• Place FireShield on the surface of the lay-up to be exposed to a heat source or flame.
• Place FireShield on both sides of a laminate or sandwich panel if it is not certain which side/surfaces will be exposed to the heat source or flame.
• The SMC should be in life (check manufacture date), and have been stored at the correct temperature.
• The SMC charge should cover the entire surface area of the tool, so that it is effectively a stamping operation.
• Die temperatures should be set to allow a maximum time for the resin at minimum viscosity, even if this extends the moulding cycle. e.g. 130 – 140°C.
• Observe surface quality after fabrication. If tacky resin is present (due to cure inhibition), a postcure temperature no higher than 190°C for two hours is recommended.
• NOTE: FireShield should NOT be subjected to temperatures above 200°C before being placed in the field.
• A cosmetic coating may be applied after fabrication. Some coatings may burn off quickly, exposing FireShield, and allowing it to create the char layer. To assess the performance, the coated part should be subjected to the fire test.
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Pultrusion Process:
To ensure correct usage of FireShield during the pultrusion process, the following are recommended:
• Wear powder-free gloves while handling FireShield.
• DO NOT dispose of non-laminated FireShield in any waste-stream. Return all off-cuts of FireShield to Regina Glass Fibre Pty Ltd (address located below) for recycling. Laminated FireShield may be disposed of per in-house waste stream practices for consolidated parts.
• Before implementing FireShield into a production environment, it is highly recommended that specimens / prototypes are fabricated to refine production parameters.
• Treat FireShield as you would a surface veil in the pultrusion process.
• Place FireShield on the surface of the pultrusion to be exposed to a heat source or flame.
• Encapsulate the entire surface of the pultrusion if it is not certain which side/surfaces will be exposed to the heat source or flame.
• If blisters result during production, reduce die temperatures. If this does not address the creation of blisters, it may be necessary to place a light-weight fibreglass veil on top of FireShield.
• Observe surface quality after fabrication. If tacky resin is present (due to cure inhibition), a postcure temperature no higher than 190°C for two hours is recommended.
• NOTE: FireShield should NOT be subjected to temperatures above 200°C before being placed in the field.
• A cosmetic coating may be applied after fabrication. Some coatings may burn off quickly, exposing FireShield, and allowing it to create the char layer. To assess the performance, the coated part should be subjected to the fire test.
Click here for a PDF Version for Print
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Vacuum Bag Resin Infusion (VBRI) Parameters:
To ensure correct usage of FireShield during the resin infusion process, the following are recommended:
• Wear powder-free gloves while handling FireShield.
• DO NOT dispose of non-laminated FireShield in any waste-stream. Return all off-cuts of FireShield to Regina Glass Fibre Pty Ltd (address located below) for recycling. Laminated FireShield may be disposed of per in-house waste stream practices for consolidated parts.
• Before implementing FireShield into a production environment, it is highly recommended that specimens / prototypes are fabricated to refine production parameters.
• Treat FireShield as you would a surface-veil for the infusion process.
• Place FireShield on the surface of the lay-up to be exposed to a heat source or flame.
• Place FireShield on both sides of a laminate or sandwich panel if it is not certain which side/surfaces will be exposed to the heat source or flame.
• Observe surface quality after fabrication. If tacky resin is present (due to cure inhibition), allow the part to fully cure using an oven for two hours at 100˚C or allowing it to fully cure overnight at 25˚C.
• NOTE: FireShield should NOT be subjected to temperatures above 200°C before being placed in the field.
• A cosmetic coating may be applied after fabrication. Some coatings may burn off quickly, exposing FireShield, and allowing it to create the char layer. To assess the performance, the coated part should be subjected to the fire test.
Click here for a PDF Version for Print
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Hand Lay-Up Process:
To ensure correct usage of FireShield during the hand lay-up process, the following are recommended:
• Wear powder-free gloves while handling FireShield.
• DO NOT dispose of non-laminated FireShield in any waste-stream. Return all off-cuts of FireShield to Regina Glass Fibre Pty Ltd (address located below) for recycling. Laminated FireShield may be disposed of per in-house waste stream practices for consolidated parts.
• Before implementing FireShield into a production environment, it is highly recommended that specimens / prototypes are fabricated to refine production parameters.
• Treat FireShield as you would a surface-veil for the hand lay-up process.
• Place FireShield on the surface of the lay-up to be exposed to a heat source or flame.
• Place FireShield on both sides of a laminate or sandwich panel if it is not certain which side/surfaces will be exposed to the heat source or flame.
• Observe surface quality after fabrication. If tacky resin is present (due to cure inhibition), allow the part to fully cure using an oven for two hours at 100 ˚C or allowing it to fully cure overnight at 25 ˚C.
• NOTE: FireShield should NOT be subjected to temperatures above 200°C before being placed in the field.
• A cosmetic coating may be applied after fabrication. Some coatings may burn off quickly, exposing FireShield and allowing it to create the char layer. To assess the performance, the coated part should be subjected to the fire test.
Click here for a PDF Version for Print
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Autoclave (Prepreg) Processing:
To ensure correct usage of FireShield during the processing of prepregs in an autoclave, the following are recommended:
• Wear powder-free gloves while handling FireShield.
• DO NOT dispose of non-laminated FireShield in any waste-stream. Return all off-cuts of FireShield to Regina Glass Fibre Pty Ltd (address located below) for recycling. Laminated FireShield may be disposed of per in-house waste stream practices for consolidated parts.
• Before implementing FireShield into a production environment, it is highly recommended that specimens / prototypes are fabricated to refine production parameters.
• Place FireShield on the surface of the lay-up to be exposed to a heat source or flame
• Place FireShield on both sides of a laminate or sandwich panel if it is not certain which side/surfaces will be exposed to the heat source or flame.
• Ensure the autoclave cure cycle temperature is below 190°C.
• It is recommended that resin-rich prepregs are used to ensure saturation of FireShield during the consolidation process. Alternatively, if the prepreg used is a low resin content type, it is recommended that a layer of epoxy film adhesive is placed between the laminate and FireShield.
• Observe surface quality after fabrication. If tacky resin is present (due to cure inhibition), a postcure temperature no higher than 190°C for two hours is recommended.
• NOTE: FireShield should NOT be subjected to temperatures above 200°C before being placed in the field.
• If the FireShield surface appears dry, an additional layer of film adhesive is recommended.
• A cosmetic coating may be applied after fabrication. An epoxy-based paint is recommended, as this will help build the char layer. Other paint coatings may burn off quickly, exposing FireShield, which then creates a stable char layer. To assess performance, the coated part should be subjected to fire testing to the relevant standard.
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