DOT/FAA/AR-00/12 Aircraft Materials Fire Test Office of Aviation Research Handbook Washington, D.C. 20591 April 2000 Final Report This document is available to the U.S. public through the National Technical Information Service (NTIS), Springfield, Virginia 22161. U.S. Department of Transportation Federal Aviation Administration NOTICE This document is disseminated under the sponsorship of the U.S. Department of Transportation in the interest of information exchange. The United States Government assumes no liability for the contents or use thereof. The United States Government does not endorse products or manufacturers. Trade or manufacturer's names appear herein solely because they are considered essential to the objective of this report. This document does not constitute FAA certification policy. Consult your local FAA aircraft certification office as to its use. This report is available at the Federal Aviation Administration William J. Hughes Technical Center's Full-Text Technical Reports page: www.actlibrary.tc.faa.gov in Adobe Acrobat portable document format (PDF). Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. DOT/FAA/AR-00/12 4. Title and Subtitle 5. Report Date AIRCRAFT MATERIALS FIRE TEST HANDBOOK April 2000 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Compiled by April Horner 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) Federal Aviation Administration Fire Safety Section, AAR-422 William J. Hughes Technical Center Atlantic City International Airport 11. Contract or Grant No. New Jersey 08405 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered U.S. Department of Transportation Final Report Federal Aviation Administration Office of Aviation Research 14. Sponsoring Agency Code ANM-100 Washington, DC 20591 15. Supplementary Notes This handbook provides information supplemental to any presently available applicable Advisory Circulars. The FAA William J. Hughes Technical Center Monitor was Richard Hill. 16. Abstract The purpose of the Aircraft Materials Fire Test Handbook is to describe all FAA-required fire test methods for aircraft materials in a consistent and detailed format. The handbook provides information to enable the user to assemble and properly use the test methods. Moreover, to broaden the utility of the handbook, the appendices contain the following information: FAA fire safety regulations, FAA approval process, aircraft materials, regulatory methodology used by other countries, aircraft industry internal test methods and guidelines, laboratories actively using fire test methods, and commercial manufacturers of fire test equipment. 17. Key Words 18. Distribution Statement Fire Safety, Aircraft interior materials, Flammability This document is available to the public through the National Technical Information Service (NTIS) Springfield, Virginia 22161. 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Price Unclassified Unclassified 234 Form DOT F1700.7 (8-72) Reproduction of completed page authorized CONTENTS Page EXECUTIVE SUMMARY xv 1.0 VERTICAL BUNSEN BURNER TEST FOR CABIN AND CARGO COMPARTMENT MATERIALS 1-1 1.1 Scope 1-1 1.2 Definitions 1-1 1.3 Test Apparatus 1-1 1.4 Test Specimens 1-4 1.5 Conditioning 1-4 1.6 Procedure 1-5 1.7 Report 1-6 1.8 Requirements 1-6 CHAPTER 1 SUPPLEMENT 1-7 2.0 45-DEGREE BUNSEN BURNER TEST FOR CARGO COMPARTMENT LINERS AND WASTE STOWAGE COMPARTMENT MATERIALS 2-1 2.1 Scope 2-1 2.2 Definitions 2-1 2.3 Test Apparatus 2-1 2.4 Test Specimens 2-4 2.5 Conditioning 2-5 2.6 Procedure 2-5 2.7 Report 2-6 2.8 Requirements 2-7 CHAPTER 2 SUPPLEMENT 2-8 3.0 HORIZONTAL BUNSEN BURNER TEST FOR CABIN, CARGO COMPARTMENT, AND MISCELLANEOUS MATERIALS 3-1 3.1 Scope 3-1 3.2 Definitions 3-1 3.3 Apparatus 3-1 3.4 Test Specimens 3-4 3.5 Conditioning 3-5 3.6 Procedure 3-5 3.7 Report 3-6 3.8 Requirements 3-6 CHAPTER 3 SUPPLEMENT 3-7 4.0 60-DEGREE BUNSEN BURNER TEST FOR ELECTRIC WIRE 4-1 4.1 Scope 4-1 4.2 Definitions 4-1 4.3 Apparatus 4-1 4.4 Test Specimens 4-3 4.5 Conditioning 4-3 4.6 Procedure 4-4 4.7 Report 4-4 4.8 Requirements 4-5 CHAPTER 4 SUPPLEMENT 4-6 5.0 HEAT RELEASE RATE TEST FOR CABIN MATERIALS 5-1 5.1 Scope 5-1 5.2 Definitions 5-1 iii 5.3 Test Apparatus 5-1 5.4 Test Specimens 5-8 5.5 Conditioning 5-8 5.6 Calibration 5-9 5.7 Test Procedure 5-10 5.8 Report 5-11 5.9 Requirements 5-11 CHAPTER 5 SUPPLEMENT 5-12 6.0 SMOKE TEST FOR CABIN MATERIALS 6-1 6.1 Scope 6-1 6.2 Definitions 6-1 6.3 Test Apparatus 6-1 6.4 Test Specimen Selection and Preparation 6-10 6.5 Specimen Conditioning 6-11 6.6 Test Chamber Calibration 6-11 6.7 Test Procedure 6-12 6.8 Report 6-13 6.9 Requirements 6-13 CHAPTER 6 SUPPLEMENT 6-14 7.0 OIL BURNER TEST FOR SEAT CUSHIONS 7-1 7.1 Scope 7-1 7.2 Definitions 7-1 7.3 Apparatus 7-1 7.4 Test Specimens 7-6 7.5 Specimen Conditioning 7-8 7.6 Preparation of Apparatus 7-8 7.7 Calibration 7-9 7.8 Test Procedure 7-9 7.9 Report 7-10 7.10 Requirements 7-10 CHAPTER 7 SUPPLEMENT 7-11 8.0 OIL BURNER TEST FOR CARGO LINERS 8-1 8.1 Scope 8-1 8.2 Definitions 8-1 8.3 Apparatus 8-1 8.4 Test Specimen(s) 8-6 8.5 Specimen Conditioning 8-6 8.6 Preparation of Apparatus 8-6 8.7 Calibration 8-7 8.8 Procedure 8-7 8.9 Report 8-8 8.10 Requirements 8-8 CHAPTER 8 SUPPLEMENT 8-9 9.0 RADIANT HEAT TESTING OF EVACUATION SLIDES, RAMPS, AND RAFTS 9-1 9.1 Scope 9-1 9.2 Definition 9-1 9.3 Test Apparatus 9-1 9.4 Test Specimens 9-3 9.5 Conditioning 9-3 9.6 Calibration 9-3 9.7 Procedure 9-4 iv 9.8 Report 9-4 9.9 Requirement 9-4 CHAPTER 9 SUPPLEMENT 9-5 10.0 FIRE CONTAINMENT TEST OF WASTE STOWAGE COMPARTMENTS 10-1 10.1 Scope 10-1 10.2 Definitions 10-1 10.3 Test Apparatus/Equipment 10-2 10.4 Test Unit 10-3 10.5 Test Arrangements 10-3 10.6 Procedure 10-4 10.7 Report 10-6 10.8 Requirements 10-7 CHAPTER 10 SUPPLEMENT 10-8 11.0 POWERPLANT HOSE ASSEMBLIES TEST 11-1 11.1 Scope 11-1 11.2 Definitions 11-1 11.3 Apparatus 11-1 11.4 Test Specimens 11-10 11.5 Calibration 11-10 11.6 Procedure 11-11 11.7 Report 11-12 11.8 Requirements 11-12 CHAPTER 11 SUPPLEMENT 11-13 12.0 POWERPLANT FIRE PENETRATION TEST 12-1 12.1 Scope 12-1 12.2 Definitions 12-1 12.3 Apparatus 12-1 12.4 Test Specimens 12-3 12.5 Conditioning 12-3 12.6 Calibration 12-3 12.7 Procedure 12-4 12.8 Report 12-4 12.9 Requirements 12-5 CHAPTER 12 SUPPLEMENT 12-6 13.0 TEST FOR ELECTRICAL CONNECTORS USED IN FIREWALLS 13-1 13.1 Scope 13-1 13.2 Definitions 13-1 13.3 Apparatus 13-1 13.4 Test Specimens 13-2 13.5 Procedure 13-5 13.6 Report 13-7 13.7 Requirements 13-7 CHAPTER 13 SUPPLEMENT 13-8 14.0 TEST FOR ELECTRICAL WIRE USED IN DESIGNATED FIRE ZONES 14-1 14.1 Scope 14-1 14.2 Definitions 14-1 14.3 Apparatus 14-1 14.4 Test Specimens 14-4 14.5 Conditioning/Preparation of Test Specimens 14-4 14.6 Calibration 14-5 v 14.7 Procedure 14-5 14.8 Report 14-6 14.9 Requirements 14-7 CHAPTER 14 SUPPLEMENT 14-8 15.0 TWO GALLON PER HOUR OIL BURNER CERTIFICATION TESTING FOR REPAIRED CARGO COMPARTMENT LINERS 15-1 15.1 Scope 15-1 15.2 Test Specimens 15-1 15.3 Specimen Conditioning 15-3 15.4 Procedure 15-3 15.5 Report 15-4 15.6 Requirements 15-5 16.0 RESERVED 16-1 17.0 RESERVED 17-1 18.0 RECOMMENDED PROCEDURE FOR THE 4-PLY HORIZONTAL FLAMMABILITY TEST FOR AIRCRAFT BLANKETS 18-1 18.1 Scope 18-1 18.2 Definitions 18-1 18.3 Test Apparatus 18-1 18.4 Test Specimens 18-4 18.5 Conditioning 18-4 18.6 Procedure 18-4 18.7 Report 18-5 18.8 Requirements 18-6 CHAPTER 18 SUPPLEMENT 18-7 19.0 SMOKE TEST FOR INSULATED AIRCRAFT WIRE 19-1 19.1 Scope 19-1 19.2 Definitions 19-1 19.3 Test Apparatus 19-1 19.4 Test Specimen Selection and Preparation 19-10 19.5 Test Chamber Calibration 19-12 19.6 Procedure 19-13 19.7 Report 19-14 CHAPTER 19 SUPPLEMENT 19-15 20.0 DRY ARC TRACKING TEST PROCEDURE 20-1 20.1 Purpose 20-1 20.2 Test Specimens 20-1 20.3 Procedure 20-2 20.4 Report 20-2 21.0 DRY ARC-PROPAGATION RESISTANCE 21-1 21.1 Purpose 21-1 21.2 Test Equipment 21-1 21.3 Test Samples 21-2 21.4 Procedure 21-2 21.5 Results 21-5 21.6 Information Required in the Individual Specification 21-6 22.0 COTTON SWAB TEST FOR THERMAL ACOUSTIC INSULATION BLANKETS 22-1 22.1 Scope 22-1 22.2 Definitions 22-1 vi 22.3 Test Apparatus 22-1 22.4 Test Specimens 22-1 22.5 Test Procedure 22-2 22.6 Report 22-2 22.7 Requirements 22-2 APPENDIX A: FAA REGULATIONS A-1 A.1 A Brief History of Federal Agencies Regulating Aviation A-1 A.2 Organization of the FAA A-2 A.3 Enabling Legislation and Procedures for the FAA A-4 A.4. Documentary Sources for Flammability Requirements A-8 APPENDIX B: THE APPROVAL PROCESS B-1 B.1 Introduction B-1 B.2 Approval Steps Manufacturers B-1 B.3 Approval Steps—Operators B-10 APPENDIX C: MATERIALS USED IN AIRCRAFT C-1 C.1 Introduction C-1 C.2 Aircraft Seats C-1 C.3 Insulating Materials C-2 C.4 Interior Panel Structures C-3 C.5 Floor Coverings C-5 C.6 Draperies C-6 C.7 Nonmetallic Air Ducting C-6 C.8 Linings (Nonpanel) C-6 C.9 Electrical Components C-7 C.10 Firewalls C-7 C.11 Windows C-7 C.12 Small Parts C-8 APPENDIX D: REGULATORY METHODOLOGY USED BY OTHER COUNTRIES D-1 D.1 Introduction D-1 D.2 Foreign Airworthiness Authorities and Regulations D-1 D.3 Regulations Covering Foreign Air Carriers D-1 D.4 Certification of Foreign-Manufactured Aircraft D-1 APPENDIX E: AIRCRAFT INDUSTRIES INTERNAL TEST METHODS AND GUIDELINES E-1 APPENDIX F: LABORATORIES ACTIVELY USING FIRE TEST PROCEDURES F-1 APPENDIX G: COMMERCIAL MANUFACTURERS OF FIRE TEST EQUIPMENT G-1 vii LIST OF ILLUSTRATIONS Figure Page 1-1 Sketch of Vertical Bunsen Burner Test Cabinet 1-2 1-2 Front and Top View of Vertical Bunsen Burner Test Cabinet 1-2 1-3 Vertical Bunsen Burner Test Specimen Holder 1-3 1-4 Burner Plumbing and Burner Flame Height Indicator 1-3 1-5 Flame Position on Vertical Specimens 1-5 2-1 Sketch of 30-Second, 45-Degree Bunsen Burner Test Cabinet 2-2 2-2 Front and Top View of 30-Second, 45-Degree Bunsen Burner Test Cabinet 2-2 2-3 Side Views of 30-Second, 45-Degree Bunsen Burner Test Cabinet 2-3 2-4 30-Second, 45-Degree Bunsen Burner Test Specimen Frame and Stand 2-3 2-5 Burner Plumbing and Burner Flame Height Indicator 2-4 2-6 Flame Position on 30-Second, 45-Degree Bunsen Burner Test Specimen 2-6 3-1 Sketch of Horizontal Bunsen Burner Test Cabinet 3-1 3-2 Front and Top View of Horizontal Bunsen Burner Test Cabinet 3-2 3-3 Side View of Horizontal Bunsen Burner Test Cabinet 3-2 3-4 Horizontal Bunsen Burner Test Specimen Holder 3-3 3-5 Burner Plumbing and Burner Flame Height Indicator 3-4 3-6 Typical Burner and Specimen Location 3-5 4-1 60-Degree Electrical Wire Bunsen Burner Test Setup 4-2 4-2 Burner Plumbing and Burner Flame Height Indicator 4-3 4-3 Alternative Setup for 60-Degree Electrical Wire Bunsen Burner Test 4-7 5-1a Rate of Heat Release Apparatus 5-2 5-1b Rate of Heat Release Apparatus 5-3 5-2 Thermopile 5-4 5-3 Side View—Global Radiant Heat Panel 5-5 5-4 Heat Release Specimen Holder, Mounting Bracket, and Drip Pan 5-6 5-5 Lower Pilot Burner Igniter Schematic 5-7 5-6 Upper Pilot Burner - 15 Hole Burner 5-7 5-7 Typical Calibration Burner 5-9 6-1 Typical Smoke Density Chamber 6-1 6-2 Furnace Section 6-3 6-3 Heater Orientation 6-3 6-4 Alignment of Holder and Burner 6-4 6-5 Flame Size 6-5 6-6 Details of Specimen Holder 6-6 6-7 Typical Furnace Support 6-7 6-8 Photometer Detail 6-8 6-9 Photometer Location 6-9 6-10 Burner Position (Optional) 6-14 viii 7-1 Front, Side, and Top Views of Seat Oil Burner Specimen Frame 7-2 7-2 Top and Side View of Specimen Setup in Test Frame 7-2 7-3a Burner Cone Layout and Bending Pattern 7-3 7-3b Burner and Cone Details 7-3 7-4 Illustration for the Location of the Air Velocity Sensor 7-4 7-5 Top and Side Views of Calorimeter Bracket 7-5 7-6 Top and Side Views of Thermocouple Rack Bracket 7-5 7-7 Example of Production Seat Configuration and Test Specimen Set to Substantiate Production Seat Bottom Cushion 7-7 7-8 Specimen Set to Substantiate Production Seat Bottom and Specimen Set to Substantiate Production Seat Back 7-7 7-9 Example of Production Seat Configuration Using Two Dress Cover Materials and Test Specimen Set to Substantiate Dress Cover Combination 7-8 7-10 Static Disk Illustration 7-13 8-1 Test Apparatus for Horizontal and Vertical Mounting for Cargo Liner Oil Burner Testing 8-1 8-2 Cargo Liner Test Specimen Frame 8-2 8-3 Cargo Liner Test Specimen Retaining Frame 8-2 8-4a Burner Cone Layout and Bending Pattern 8-3 8-4b Burner Cone Details 8-3 8-5 Top and Side Views of Calorimeter Bracket 8-4 8-6 Top and Side View of Thermocouple Rake Bracket 8-5 8-7 Illustration for the Location of the Air Velocity Sensor 8-6 8-8 Static Disk Illustration 8-10 9-1 Evacuation Slide Material Test Apparatus – Front View 9-1 9-2 Evacuation Slide Material Test Apparatus – Side View 9-2 9-3 Evacuation Slide Material Test Apparatus – Top View 9-2 9-4 Furnace Details 9-2 10-1 Sample Fire Containment Temperature versus Time Plot 10-6 11-1 Burner Extension Funnel 11-5 11-2 Air Tube Reducing Cone 11-5 11-3 Hose Assemblies Test Setup 11-6 11-4 Burner Calibration Standardization Apparatus 11-7 11-5 Btu Heat Transfer Device 11-7 11-6 Btu Heat Transfer Device—Reducer 11-7 11-7 Btu Heat Transfer Device—Inlet Tube 11-8 11-8 Btu Heat Transfer Device—Outlet Tube 11-8 11-9 Btu Heat Transfer Device—Thermometer Mounting 11-8 11-10 Btu Heat Transfer Device—Test Specimen 11-9 12-1 Firewall Penetration Test Setup—Top View 12-2 13-1 Firewall Connector Test Setup 13-3 13-2 Firewall Connector Fixture Assembly 13-4 13-3 Firewall Connector Fixture Details 13-5 ix