Why Fire Performance Matters Earlier Than Ever

Whether developing a new polymer compound, protective coating, composite, or construction material, understanding fire behaviour has become an essential part of product development. Increasing safety requirements, stricter regulations, and growing customer expectations mean that manufacturers can no longer rely solely on conventional flammability classifications at the end of the development cycle.

Instead, engineers increasingly use advanced fire characterization techniques during material development to compare formulations, optimize fire performance, and identify promising candidates before moving to larger-scale qualification testing.

Recently, EXPERTA | TESTING supported a customer with an independent fire performance assessment of multiple material formulations. Working together with one of our specialized European laboratory partners, we coordinated the complete testing process—from selecting the appropriate methodology to delivering technically sound results for further product development.

The Challenge

The customer was developing several material formulations and needed objective data to compare their combustion behaviour under controlled laboratory conditions.

The objective was not simply to determine whether a material passed or failed a fire classification. Instead, the engineering team wanted deeper insight into how different formulations behaved during thermal decomposition and combustion, allowing them to make informed decisions during material optimisation.

Because several candidate materials had to be evaluated under identical conditions, consistency, repeatability, and compliance with internationally recognised testing procedures were essential.

Selecting the Right Test Method

After reviewing the application requirements, EXPERTA | TESTING recommended Microscale Combustion Calorimetry (MCC), performed according to ASTM D7309.

Although MCC is performed on small test specimens, it provides highly valuable information regarding a material's combustion characteristics. It is widely used during research and development because it enables engineers to compare multiple formulations quickly while requiring only a limited amount of material.

Rather than performing large-scale fire tests immediately, MCC helps identify trends and supports material selection before proceeding to more extensive qualification programmes.

The technique measures the heat released during controlled thermal decomposition of a material. During the test, specimens are heated under precisely controlled conditions while combustion gases are completely oxidised. By measuring oxygen consumption, several combustion characteristics can be determined.

This approach provides developers with quantitative information that can be used to compare material behaviour during product development.

Our Engineering Approach

As with every project, our role extended beyond arranging laboratory capacity.

Our engineers first discussed the customer's objectives to determine which fire testing methodology would generate the most meaningful engineering information.

After selecting the appropriate laboratory within our European partner network, we coordinated the complete testing programme, including:

• Technical review of the testing requirements
• Selection of the appropriate ASTM testing methodology
• Sample logistics and laboratory coordination
• Monitoring of the testing process
• Technical review of the laboratory data
• Delivery of a structured engineering report for the customer

All testing was performed under controlled laboratory conditions using calibrated equipment following the ASTM D7309 test procedure.

Multiple material samples were conditioned prior to testing before being evaluated under identical experimental conditions to ensure reliable comparison between formulations.

What Engineers Can Learn from Microscale Combustion Calorimetry

Unlike traditional pass/fail fire tests, MCC generates engineering data that supports material development decisions.

Depending on the application, engineers can evaluate characteristics such as:

• Heat release behaviour
• Thermal decomposition characteristics
• Combustion efficiency
• Heat release capacity
• Repeatability between formulations
• Relative fire performance during early development

These insights allow R&D teams to compare material modifications before investing in larger and more expensive fire qualification programmes.

The information is particularly valuable when developing:

• Polymer compounds
• Flame-retardant formulations
• Composite materials
• Coatings
• Lightweight engineering materials
• Materials for transportation or construction applications

It is important to recognise that microscale combustion calorimetry is intended as a material characterisation technique. Like many laboratory methods, the results should be interpreted within the context of the specific test conditions and are not intended to predict complete fire behaviour in real-life applications.

The Value of Independent Laboratory Expertise

One of the strengths of EXPERTA | TESTING is that we remain independent.

Rather than being limited to a single laboratory or a fixed set of equipment, we work with more than 450 specialised laboratory partners across Europe. This enables us to select the laboratory with the most appropriate expertise for each individual project.

For our customers, this means:

• Independent advice on the most suitable test methodology
• Access to specialised laboratories that may otherwise be difficult to identify
• One technical point of contact throughout the project
• Faster access to advanced testing capabilities
• Reliable interpretation of laboratory results within the engineering context

Our objective is not simply to execute tests, but to help customers obtain the technical information needed to make better engineering decisions.

Expanded Fire Testing Capabilities

To further support manufacturers during product development and qualification, our European laboratory network has recently expanded its fire testing capabilities.

Customers can now access an even broader range of fire resistance testing services covering:

• Materials
• Plastics
• Protective coatings
• Construction materials

These testing capabilities support product development, fire safety evaluation, compliance programmes, and material qualification across various industries.

Whether the requirement involves early-stage material screening using microscale combustion calorimetry or more extensive fire resistance evaluations, EXPERTA | TESTING can help identify the most appropriate laboratory and testing strategy for your application.

Looking for the Right Fire Testing Solution?

Every material presents different fire performance challenges, and selecting the appropriate test method is often just as important as the test itself.

At EXPERTA | TESTING, we combine more than 25 years of engineering experience with access to an extensive European laboratory network to help customers find the right testing solution for their specific application.

If you are developing new materials or need independent advice on fire performance testing, our engineers are happy to discuss the most suitable testing strategy for your project.