Why Fire Performance Matters Earlier Than Ever
Whether developing a new polymer compound, protective coating, composite, or construction material, understanding fire behavior 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 behavior 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 optimization.
Because several candidate materials had to be evaluated under identical conditions, consistency, repeatability, and compliance with internationally recognized testing procedures were essential.
Selecting the Right Test Method
After reviewing the application requirements, EXPERTA | TESTING recommended Pyrolysis Combustion Flow Calorimeter (PCFC), performed according to ASTM D7309.
Although PCFC 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, PCFC helps identify trends and supports material selection before proceeding to more extensive qualification programs.
The specimen is first heated at a constant rate of temperature rise (typically 1°C/s) in a pyrolyzer and the degradation products are purged from the pyrolyzer by an inert gas (nitrogen). The gas stream is mixed with oxygen and enters a combustor at 900°C where the decomposition of products are completely oxidized. Oxygen concentrations and flow rates of the combustion gases are used to determine the oxygen consumption involved in the combustion process and the heat release rates are determined from these measurements.
This approach provides developers with quantitative information that can be used to compare material behavior during product development.
Our Engineering Approach
As with every project, our role extended beyond arranging laboratory capacity.
Our engineer 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 program, 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, PCFC generates engineering data that supports material development decisions.
Micro Calorimeter data has been shown to correlate with fire test data (Cone Calorimeter), flammability results (acc. UL94) and combustion tests (e.g. Bomb Calorimeter) and is therefore seen as a powerful tool to assess and predict flammability properties.
Depending on the application, engineers can evaluate characteristics such as:
- Heat release behavior
- 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 programs.
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 recognize that microscale combustion calorimetry is intended as a material characterization 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 behavior 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 specialized 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 specialized 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
- Protective coatings
- Protective textiles
- Personal Protective Equipment
These testing capabilities support product development, fire safety evaluation, compliance programs, and material qualification across various industries.
Whether the requirement involves early-stage material screening using microscale combustion calorimetry or more extensive fire resistance evaluations, we 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.
More info: info@experta-testing.com