Thomas Izbicki, P.E. Rolf Jensen & Associates, Inc. Plano, TX Basics of NFPA 45 – Standard on Fire Protection for Laboratories Using Chemicals Thomas Izbicki, P.E. Rolf Jensen & Associates, Inc. Plano, TX

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Presentation Overview What is a Laboratory? Laboratory Unit Classification Flammable and Combustible Liquid Limits Fire Protection Explosion Hazards Laboratory Ventilation Chemical Storage and Handling Gas Storage and Use Laboratory Operations Hazard Identification

What is a Laboratory? Laboratory A workplace where chemicals are used or synthesized on a non-production basis. A facility where the containers used for reactions, transfers, and handling of chemicals are designed to be manipulated by one person.

What is a Laboratory? Laboratory Work Area A room or space for testing, analysis, research, instruction, or similar activities that involve the use of chemicals.

What is a Laboratory? Laboratory Unit An enclosed space used for experiments or tests. May include one or more laboratory work areas. May include offices, lavatories, corridors, and other incidental contiguous rooms. May be a floor in a building May be an entire building.

What is a Laboratory? Laboratory Building A structure consisting wholly or principally of one or more laboratory units.

Laboratory Units NFPA 45-2004 edition, Figure D.2.4(a)

Laboratory Units NFPA 45-2004 edition, Figure D.2.4(b) NFPA 45-2004 edition, Figure D.2.4(c)

Laboratory Units NFPA 45-2004 edition, Figure D.2.4(d) NFPA 45-2004 edition, Figure D.2.4(e)

Applicability of NFPA 45 NFPA 45-2004 edition, Figure A.1.3

Objective of NFPA 45 Limit injury to: Occupants at the point of fire origin Emergency response personnel Limit property loss to a single laboratory unit

Laboratory Unit Fire Hazard Classification Class A Unit = High Fire Hazard Class B Unit = Moderate Fire Hazard Class C Unit = Low Fire Hazard Class D Unit = Minimal Fire Hazard

Laboratory Unit Classification Based on the quantity of: Flammable liquids Combustible liquids Flammable gases Includes quantities in storage and use

Laboratory Unit Classification Liquefied flammable gases = Class I flammable liquids How to classify hazardous materials? CD ROM database: Hazardous Materials Expert Assistant www.iccsafe.org Ask users to inventory existing materials Look at worst-case user – types and quantity

Laboratory Unit Classification Includes quantities in storage cabinets or safety cans Lab Unit Classification Maximum Quantity Class I Liquids per Lab Unit (gal) Class I, II, IIIA Liquids per Lab Unit (gal) A 20 gal/100 ft2 1,200 (max) 40 gal/100 ft2 1600 max B 10 gal/100 ft2 600 max 800 max C 4 gal/100 ft2 300 max 8 gal/100 ft2 400 max D 2 gal/100 ft2 150 max

Laboratory Unit Classification Lab Unit Classification NFPA 101 Occupancy Classification Area Limit per Lab Unit (ft2) Vertical Fire Separation (hours) A Industrial 10,000 2 90-min openings B 1 45-min openings C No Limit Not Required D Business

Laboratory Unit Classification No limit on number of lab units per floor No reduction of allowable quantities based on vertical location Supporting construction must carry corresponding fire rating Difficult to do Class A/B lab units in multi-story Type IIB building!

Lab Units vs. IBC Control Areas IBC/IFC Maximum Allowable Quantity (MAQ) Hazardous Materials Physical/Fire Hazards Health Hazard Control Areas Control Area ~ Lab Unit Some jurisdictions require application of both control areas and lab units – use most restrictive

Laboratory Unit Exit Access 2nd means of exit access required from lab work area if: Class A lab unit >500 ft2 Class B, C, or D lab unit >1,000 ft2 Threat to exit access from: Explosion hazard Hood adjacent to primary exit access Flammable gas or health hazard 3 or 4 >lecture bottle size Cryogenic flammable gas or health hazard 3 or 4

Laboratory Unit Exit Access Exit access door swing Class A and B lab work areas Direction of exit travel Any occupant load Class C and D lab work areas May swing against the direction of exit travel if occupant load < 50 May be a horizontal sliding door per NFPA 101

Fire Protection Automatic sprinkler system required in all new labs Sprinkler Density: Ordinary Hazard Group 2 – A/B lab units Ordinary Hazard Group 1 – C/D lab units Portable Fire Extinguishers Class A Units = Extra (high) Hazard Class B, C, D Units = Ordinary (moderate) Hazard Standpipes Lab buildings 2 or more stories above or below grade

Fire Protection Fire Alarm System Fire Prevention Procedures Class A and B Units – manual system required Must alert local emergency responders or public fire department Fire Prevention Procedures Chemical handling and storage Hot work permits Portable electric cords Smoking areas

Fire Protection Laboratory Emergency Plans Alarm activation Evacuation and building re-entry Equipment shut down Fire fighting operations Non-fire hazards that threaten emergency operations

Explosion Hazards Storage or formation of materials with an instability hazard rating of 4 Highly exothermic reactions Polymerization, oxidations, hydrogenation, etc. High pressure reactions Explosion hazards as determined by a qualified person

Explosion Protection Limit amounts of flammable or reactive chemicals Fire detection interlocked with deluge sprinklers Local fume hood suppression Explosion suppression Explosion resistant construction Explosion venting

Laboratory Ventilation Dedicated exhaust required for each lab unit – to exterior, or rated shaft, or to mechanical penthouse Fire dampers not permitted in lab exhaust duct systems Potential alternatives: Enclose exhaust for 10 feet either side of rated penetration Use sub-ducts per NFPA 45: A.8.10.3.1 Dedicated exhaust duct risers 22-inch sub-ducts with continuous upward air movement

Laboratory Ventilation Negative pressure vs. corridors and non-lab area Ducts Non-combustible materials Combustible material with Flame Spread ≤ 25 Fans Conveying corrosive, flammable or combustible vapors Flame Spread ≤ 25 Non-ferrous or spark-resistant

Laboratory Ventilation Hood interiors Flame Spread ≤ 25 by NFPA 255 Sprinklered for special cases Flame spread > 25 Hazard analysis Airflow measuring device at each hood

Chemical Storage and Handling Container types and maximum sizes listed in Table 10.1.4: Material Flammable liquids Combustible liquids Container type Glass Safety can Metal and Metal DOT Polyethylene

Chemical Storage and Handling Educational and Instructional Labs Containers Maximum 2.1 gallon size for Class I or Class II liquids 1.0 gallon maximum for safety cans Transfer of Class I liquids from < 5 gallon containers: In lab hood Ventilated area with LEL < 25% NFPA 30 compliant room Transfer of Class I liquids from ≥ 5 gallon containers: In separate area outside building; or In NFPA 30 compliant room

Gas Storage and Use Ventilated hood required for lecture bottles: Health hazard 3 or 4 Health hazard 2 with no physiological warning properties Pyrophoric gases Gas cabinet and NFPA 55 compliance required for cylinders: Health hazard 2 with no warning properties Sprinklered gas cabinet required for pyrophoric gas cylinders

Gas Storage and Use Gas quantity limits for areas < 500ft2: Flammable – 6.0 ft3 Oxidizing – 6.0 ft3 Liquefied flammable – 1.2 ft3 Health hazard 3 or 4 – 0.3 ft3

Gas Storage and Use Gas quantity limits for areas >500ft2: Flammable – 0.012 ft3 per ft2 Oxidizing – 0.012 ft3 per ft2 Liquefied flammable – 0.0018 ft3 per ft2 Health hazard 3 or 4 – 0.0006 ft3 per ft2

Gas Storage and Use Cylinders not “in use” shall not be stored in a laboratory unit. Number of lecture bottles – 25 maximum Outdoor storage No toxic or flammable gas cylinders: Within 6 feet of windows, doors, other openings Within 30 feet of ventilation intakes

Laboratory Operations Unattended electrical heating operations Manual reset over-temperature shutoff Electrical equipment (eg. hot plates) classified for flammable or combustible liquids and installed per NFPA 70, National Electric Code Ovens and Furnaces – per NFPA 86

Hazard Identification Aid Emergency Operations Identification of entrances to labs Fire fighting plans Marking of hazardous exhaust systems Container labeling

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