Theoretical Formulation Development
The in-house capability for product development is unique. Much of the early development is theoretical, based upon the mathematical model developed by FPW. This work is conducted in the analytical laboratory and allows for accurate assessment of insulation values for the char.
Formulation Screening
FPW has developed a novel screening process. This process is three fold, with the initial tests being conducted in fixed temperature furnaces, over a fixed period of time and assessed for char properties. The second process is to test on a steel plate, in the bespoke gas scale furnace. This has been calibrated to meet the curves and radiation levels of the main test centres in UK and USA. The final test in the screening phase is conducted on a modified column coated and run to the required fire regime. The first two processes allow for an efficient method to refine the formulation before more costly column tests are conducted.
Formulation Verification
Once the screening tests are completed, the formulations have completed a rigorous testing program (to validate them internally). Larger scale tests can be conducted to look at other properties of the char which are less apparent in the screening phase, due to size of the test samples. 1m columns and 1.8m column samples can be tested internally. The regimes run accurately to the test centres, therefore giving a high level of confidence of test meeting the expected fire resistance periods.
External Validation
To achieve final certification, the formulations need to be tested at the independent test centres. There are a number of these facilities in the UK which will give global accreditation, including Warrington Research Centre, BRE, GL Nobel Denton and HSL laboratories. FPW has access to these centres, and have tested at each of these facilities extensively in the past.