INTRODUCTION:

The concept of protecting textiles / garments from burning dates back to ancient
times or at least to the middle ages.

Fire takes a steady toll of both human life and property. The results are often tragic
and in many cases (at least potentially) avoidable.

Just three minutes after ignition a fire can become a full-blown blaze. At a
conservative estimate, death from asphyxiation is likely to occur within four minutes.

Every fire is a potential killer and delaying the time from ignition to full blown blaze
even by just minutes can mean vital extra escape time and the difference between
SURVIVAL and DEATH.

In the beginning awareness of flame-retardants would have avoided the major
disaster to a large extent. Due to fire occurring in public places, horrific loss of life has
occurred


Why Flame Retardants:

Flame retardants can and do save
lives, both by preventing garments
from igniting and by increasing the
escape time in the event of a fire up to
15 fold.
A flame retardant finish will not always
be sufficient to stop a fire breaking out.

Flame Retardants are effective at preventing propagation of
flame started by a small ignition source but larger fires pose
more of a problem. Because it is smoke that is invariably the
killer, the perfect. Flame retardant would also reduce the
production of toxic products in the smoke.


Despite improved methods of fire detection and prevention,
accidental house fires do still, and will continue to happen and it is
the smoke a mixture of gases, liquid droplets and solid particles
representing the decomposition and combustion products from fires
that presents the real treat to human life.
The problem has many components, which can be summarized as
follows:
A wide range of commonly used materials is flammable.
A range of situations, in theatres, restaurants, clubs and
aircraft can cause heavy loss of life in the event of fire.


THE RISKS:

Progress in reducing the fire hazard has been
made, but is constrained by a series of factors.

The risk is not widely appreciated by the
general public, except when a major disaster
occurs.

Any solution, which restricts personal freedom,
is likely to be avoided by a significant number of
people.

Any product with reduced aesthetic and comfort
qualities will be less successful even if it has fire
retardant properties.

Any solution, which adds significantly to
product cost, may be resisted by the processor.
FIBRE PROPERTIES:
The flammability of fabrics is
influenced by the inherent
characteristics of different types of
fibers and their blends. The
flammability characteristics of
commercially available fibres vary
widely as seen from Table 1.





FIBRE PROPERTIES:




Fibre Auto
Ignition
temp.
(C)
Maximum
flame temp
(C)
Flammability
Cotton 400 860 Burns readily with char formation
and afterglow
Rayon 420 850 Burns readily with char formation
and afterglow.
Acetate 475 960 Burns and melts ahead of flame.
Triacetate 540 885 Burns readily and melts ahead of
flame
Nylon 6 530 875 Melts, supports combustion with
difficulty.
Nylon 66 532 * Melts, does not readily support
combustion.
Polyester 450 697 Burns readily with melting and soot.
Acrylic 560 855 Burns readily with melting and
sputtering.
Modacrylic * * Melts, burns very slowly.
Poly propylene 570 839 Burns slowly.
Polyvinyl chloride
and polyvinylidene
chloride
* * Does not support combustion.
Wool 600 941 Supports combustion with difficulty.
* These fibres do not
burn.
FIBRE PROPERTIES:
Materials can be classified clearly into those which will burn in air once ignited and
those which are self extinguishing, if not in direct contact with an ignition source.
Amongst those materials, which will burn freely, two other properties may add
significantly to the hazard.

The heat of combustion : Any material with a high heat of combustion provides
increased ignition for surrounding materials. Heats of combustion can vary from
11.6 kcal/g for polypropylene down to 3.4 kcal/g for viscose rayon.

Thermal properties: A series of thermal transition temperatures covers important
events when a material is exposed to an ignition source.

Tg:The glass transition or softening temperature particularly in clear rigid plastics.

Tm:The melting point (Thermo plastics only)

Tp:Pyrolysis temperature: rapid thermal degradation of the polymer.

Tc:Combustion temperature: Spontaneous ignition occurs.

Some materials such as wool and modacrylic have a Tc as high as 600 - 700C and
are difficult to ignite.





LIMITING OXYGEN INDEX :

The atmosphere contains about 21% oxygen. The
rest (nitrogen, CO
2
, water, noble gases etc.) does
not support combustion. It has been
experimentally found that increasing the ratio of
O
2
to N
2
makes some materials burn that are self
extinguishing in air. Conversely, materials, which
burn readily in the air, are self-extinguishing in
nitrogen - rich atmosphere.

This leads to a useful and general test for
classifying flammability. The limiting oxygen index
(LOI) test seeks to establish the minimum oxygen
content of an environment in which a material will
continue to burn.

The material with the LOI greater than 25 are
generally self-extinguishing in air. Those with the
lowest LOI values burn most readily very few
materials indeed refuse to burn in atmosphere
approaching 100% O
2
. The LOI values of various
fibres are given in Table 2.




LOI VALUES OF VARIOUS FIBRES


*
*Aramid fibre

Fibre LOI Fibre LOI
Poly acrylonityle 18.0 Nylon 66 23.0
Polyethylene 18.0 Wool 25.2
Polystyrene 18.5 Modacrylic 26.8
Cellulose 19.0 Nomex* 28.5
Poly ethylene
terephthalate
21.0 Tufban* 30.32
Polyvinyl alcohol 22.0 Polyvinyl 60.0
Polytetra-
fluoroethylene
95.0
REQUIRED LOI VALUES OF VARIOUS FABRICS


*

Area of use Fabric End use LOI
(Minimum)
Wearing Childrens wear 28
Old mens wear 28
Sleepwear 28
Wigs 27
Interior goods Curtain 29-30
Carpet 24-26
Wall cloth 25
Bedding Bedding 24
Blanket 24
Sheets 24
THE COMBUSTION PROCESS :

The major contribution to saving life is to Retard the combustion
process. In order to understand how flammability hazards can be
reduced, it is necessary to study the nature of the combustion
process. Combustion can very easily develop into a run-away, self-
feeding events producing enormous heat, suffocating and toxic
fumes and total destruction.

The essential components for burning:

Ignition source
Fuel
An oxidant (usually oxygen of the
air)



THE COMBUSTION PROCESS :

Heat and fumes feed back readily burned gases and
give increased ignition. The rate of combustion
increases and can reach explosive violence in so-called
flash over events and such an event cause major loss
of life.

The bulk of the material that is burnt in a typical
house fire plastics, wood and textiles is made up of
combustible organic compounds. In theory, a well-
ventilated fire with efficient combustion will product
low toxicity
products, mainly CO
2
, H
2
O and heat.

But real fires bear little resemblance to theoretical
models: Inefficient combustion process, combined
with the more complicated elemental composition of
the materials being decomposed, result in a complex
mix of combustion products, many of which are toxic.
Over many years a four-fold attack has been mounted
on loss of life and injury by fire.

THE COMBUSTION PROCESS :

There are tour types of products that
cause concern.

1. Asphyxiant gases (CO, HCN and CO
2

etc.)
2. Organic irritants (e.g. acrolein,
crotonaldehyde, formaldehyde,
phenol, styrene).
3. Inorganic irritants (oxides of nitrogen
and sulphur and phosphates)
4. Exotics Substances such as dioxine,
fluoro carbons and isocyanate
derivatives which may have long term
health or environmental hazards.


THE COMBUSTION PROCESS :

The two predominant mechanisms by which flame-retardants act
are in:
1. Solid or condensed-phase and
2. In gas-phase retardation of combustible products.

Concomitant increases in the formation of char, carbon dioxide and
water occur when solid-phase mechanism is operative. Reduction
of volatile, flammable products by the condensed-phase mode is
affected by dehydration and/or cross-linking. Although these
modes of action are well established for cellulosic fibers, more
detailed studies are needed to elucidate the precise modes of
condensed-phase behavior in the case of other fibres.
In combination with the particulates in the smoke, which impair
vision, the organic and inorganic irritants impede escape attempts
because of their painful effects on the eyes and respiratory tract.
The asphyxiant gases cause incapacitation and eventually death.


The mechanism of burning of textiles :








Oxidizer
Heat Flame
Combustible gases
Polymer Non combustible gases
Liquids (partially decomposed polymers)
Solids (carbonaceous residues or char)
Smoke (entrained solid or liquid particles)

Heat

Decomposition

Ignition

Combustion

Non-flaming degradation Flame Propagation

Physical response,Shrinkage,
melting, charring

Gaseous products of the combustion of organic polymers


*
*Aramid fibre

Source Gaseous products of
combustion
Wool, silk, nitrogen-
containing polymers (PAN,
ABS, polyurethanes, nylons,
amino
resins, etc.)
HCN, NO, NO
2
, NH
3

Vulcanized rubbers, sulfur-
containing polymers, wool
SO
2
, H
2
S, CO
2
, CS
2

PVC, PTFE, polymers
containing halogenated flame
retardants, etc.
HCI, HF, HBr
Polyolefins and many other
organic polymers Polystyrene,
PVC, polyesters, etc.
Alkanes, alkenes Benzene
Phenolic resins Phenol, aldehydes
Wood, paper Acrolein
Polyacetals Formaldehyde
Cellulosic fibers Formic and acetic adds
COMMERCIAL SOLUTIONS FOR FIRE RETARDANCY:
Design : Substantial progress has been made in the design of
buildings, aircrafts, trains, upholstery and garments to avoid
flammability and larger scale fire risks. Alongside this, progress
has been made in testing. The emphasis in testing is on complete
structures rather than individual materials, which are adequately
characterized by existing tests.

The key to designing low risk structures is based on spread of
combustion and combustion products (toxic fumes, smoke etc.)
For a given material, e.g., cellulose, the rate of combustion varies
enormously. This is illustrated by igniting two sheets of
newspaper. The first is held open and ignited at the bottom edge.
The second is rolled tightly. This burns very much more slowly
and controllably.

It is clear from this and similar observations, that fabric and
garment structure can play a substantial role in fire-retardancy.
Fine nets, free hanging edges, streamers and open structures
with free access to air, leads to maximum combustion rates and
likely points for casual ignition. By contrast heavy, closely woven
materials, multi-layer structures are free from easily ignitable
features and reduce the risk.


USES OF FLAME RETARDANT FABRICS

Flame retardant fabrics are needed for a variety of uses such
as for:
Apparels and garments - sleepwear, nightwear, children's
wear, loose garments, sarees, shawls, kitchen wear, etc.,
where there are chances of accidental contact with flame.
Uniforms for fire-fighting personnel.

Dresses, boiler suits and protective clothing for
workmen in many industries like petroleum &
petrochemicals, oils, paints & varnishes, mining, iron &
steel, explosives matches, organic chemicals & solvents,
electricity generation & distribution, foundry, welding,
petrol & diesel pumps, cooking gas storage &
distribution etc.

Home furnishing and decorations - curtains, drapes,
upholstery, bedding, mattresses, wall coverings &
trimmings etc.

Carpets and rugs.

Industrial fabrics - Brattice cloth for coal mines, carpet
backing fabrics, barrier fabric as overlay on foam and
rubber cushions, underlay in motor vehicles, wall
coverings, decorative fabrics etc.

Hotels, restaurants, clubs, rest houses, dormitories,
auditoriums, theatres, cinema halls, religious
worship & congregation halls, marriage halls,
hospitals, schools & colleges etc.

Armed Forces (Defence) - clothing for airmen & fire
fighting crew, overalls, parachutes, awnings,
tarpaulins, canvas including SKOP (Support Kit
Overhead Protection), claddings & shelters, etc.; also
for Paramilitary, Police etc.

Exports - garments, curtains, wall coverings, bed
covers, mattresses, quilts, airline furnishings,
automobile fabrics etc


FLAMMABILITY TESTING:
The tests established provide controlled reproduceable ignition systems
and measurement of following combustion. This may be either as flame
or as glowing char. Each test has been carefully compared with the
burning behaviour of garments, furnishings and carpets. In addition,
appropriate test methods lay down standardized washing and solubility
tests. These are used to assess durability of FR finishes.

Several special hazards have been identified and allowed for testing.
Both soaps and fabric softeners are flammable materials. In hard water
conditions, laundering with soaps leads to build up of lime soaps on the
fabric. These are flammable and can cause premature failure of
flammability test.
All the phosphorous containing flame retardants suffer pre-mature loss
of durability if laundered with sodium hypochlorite type of bleaching
agents.

It is important, when discussing fire retardancy and when selling fire
retardant products, to use precise terminology. If you make an ascertain
that product has low flammability or is flame resistant or does not burn
you may have to defend the statement in a court of law. Terminology,
testing and labelling must be clear and unambiguous.
1. Use approved and defined terminology.
2. Refer to BS, ISO, IS tests by which the terminology is established.
3. Ensure that the products and materials pass the appropriate test.


FLAMMABILITY TESTING:


The terms flame proof and fire proof should be avoided.
Fire retardant is a useful general term. Does not sustain
flame is the approved term. Self extinguishing is widely
used to describe materials which only burn in contact
with an ignition source.


Reduced fire hazard or resists ignition are also acceptable
terms but should only be used in connection with a
specified test. A variety of carefully designed tests is
available by which the property can be measured.

Test methods and their execution and interpretation are a
highly specialized area. Individual testing houses set up
appropriate apparatus, trained staff and receive validation
and certification. It is common practice to use such
certified testing procedures to ensure product integrity.



List Of Some Important FR Standards:




Application Country Burning Test
Childrens sleepwear

Performance of fabrics
and assemblies for
sleep wear and
dressing gowns.
US

BS
DOC FF 3-71 and 5-74 CS 191-93

BS 5722 / BS 3119:3120 / IS 11871
Airways uniform BS British Airways FR - test 1993
Textile & furnishing Germany
Great
Britain
Europe
USA
DIN 4102-1 B2
BS 5852 Part-1 & 2
DIN EN1021-1
DIN EN 1021-2
CALIFORNIA TECH BULLETIN NO
117 SEC A / NFPA 701
Avaition Internatio
nal
JAR/FAR 25.853
Automotive Germany
USA
DIN 75 200
FMVSS 302
Protective clothing Europe DIN EN 532
CLASSIFICATION OF FLAME RETARDANTS:

These FR chemicals are often divided into non-durable, semi-durable and FR systems.
Since the costs for the non-durable FR chemicals are usually much less than the durable
systems, the non-durable FR chemicals are used wherever possible

Non Durable or Non permanent:
The flame retardant deposits on the fibre. We can offer a suitable product for all fibre
types. The products of this range are not resistant to soaking or washing, but some are
resistant to dry cleaning.

Semi-permanent flame retardants :Due to the low solubility of the components applied,
the products are resistant to soaking. This is mainly required by the furniture industry
and carried out according to the so-called soaking test BS 5651. The specimen is placed for
30 min in a 40C warm water bath, without any mechanical stress, however.

Permanent flame retardants
With cellulosic fibres, the flame retardant forms a chemical bond with the fibres reactive
groups.

The PES and PA fibres are thermally opened after the application of the flame retardant so
that it can deposit. This is the so-called thermosol process. The flame-retardant effects
obtained are highly wash-resistant on cellulosic, PES and PA fibres.




Product Glogard-NC Glogard-
CSND
Glogard-
HFR
Glogard-
PP
Glogard-
PAD
Glogard-LFR Glogard-
STU/conc
Glogard-
CP New
Glogard-
ZF
Glogard-
UDS
Composition Inorganic & organic salt blends Inorganic
phosphorus &
nitrogen
compound
cyclic
phosphonate
Organic
phosphorus
compound,
fibre-
reactive
Organo
phosphoro
us
compound
Latex
polymer,
metallic
oxides &
halogen
sources
Ionic character Nonionic Nonionic Nonionic Nonionic Nonionic Nonionic Nonionic Nonionic Nonionic Anionic



Substrate
CEL ---- -----
WO --- ----
PAN ---- ---- ----- ----
PA ---- ---- ----
PES ---- -----



Application
examples
padding
process

foam
application
---- ---- ---- ---- ---- ---- ---- ---- ----
exhaust
method
---- ---- ---- ---- ---- ---- ---- ---- ----
spray/WEK
O process
---- ---- ----
coating ---- ---- ---- ---- ---- ---- ----
Application quantity
Padding process(g/l)
400 400 400 400 400 400 100-200 350-400 150-200 400-600


Durability
resistance
to soaking
---- ---- ---- ---- ----
resistance
to washing
---- ---- ---- ---- ---- ----
resistance
to dry
cleaning

Note: Very Good : Good Satisfactory ---- Not applicable





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