Fuma - The journey to certification
MY ROLE
Head of Product Development
Project Management, Research, Concept Design, 3D CAD, Engineering, Prototyping, Supplier Relations
OVERVIEW
Since the Grenfell Tower tragedy in the UK in 2017, what was once acceptable in the construction industry is no longer.
"Each and every one of the deaths that occurred in Grenfell Tower...was avoidable"
RICHARD MILLETT KC, LEAD COUNSEL FOR THE INQUIRY
My team and I developed the worlds first true CE-marked Smoke Control Damper for the extraction of smoke during a building fire
PROJECT OBJECTIVE
CE Marked to EN 12101 Part 8.
Fire tested to EN 1634 Part 1.
Cycle tested open / close 10'000 times
FPC audited
Install the door outside the ventillation shaft
WHAT IS SMOKE CONTROL DAMPER?
A smoke extraction solution that can be integrated into a building.
When triggered by heat or smoke detectors, the damper on the floor of origin will open, allowing the smoke to be extracted.
This is normally employed to protect stairwells, allowing safe evacuation of a building.
Engineering Challenges
The Hinge MUST -
Open 180⁰.
120KG weight over 3 hinges.
Maintenance Free.
Tested to 10'000 cycles minimum.
The Actuator MUST -
Tested to 10'000 cycles
Open and close in 60 seconds
Finger trap protection
Power failure override
12 Volt power
IP69 Rating
The Latch MUST -
Tested to 10'000 cycles
Slam tested
The Insulation MUST
Extremely low thermal conductivity.
Can be processed safely.
Non-flammable.
Risks
Cost price too high to be profitable.
Door does not latch correctly.
Door jams.
Door falls in shaft.
Person falls into shaft.
Product does not meet standards.
Actuator fails before cycle requirement.
Fire test fail.
Research - Hinges
The UK's number one hinge manufacturer was the obvious choice
The hinges use a patented "Hi-Load" bearing system for maintenance free use with a 25 year guarantee.
The hinge is CE-marked and cycle tested to 1 million cycles, up to 120KG.
Research - Actuation
Several methods of actuations were investigated.
90⁰ Arm Actuator
A mechanical arm, or powered chain that attaches to the top and bottom of the door.
PRO:
High Torque.
CON:
Two units are required.
Chain Drive
A powered chain drive that attaches to the opening vertical edge of the door.
PRO:
Reliable.
CON:
Very expensive unit.
Linear Actuator
A linear actuator, or actuators, that can be mounted in various locations on the door
PRO:
High Torque.
CON:
Complicated.
Research - Latching
Rotary Latch - Reliable, mechanical solution
Electromagnetic Latch - Open / Close feedback
Research - Insulation
The insulation must provide high levels of thermal insulation to block heat transmitance through the door during a fire scenario.
Vermiculite
Spacetherm
Magnesium Oxide
Calcium Silicate
Insulation Testing within a steel door sample
Prototyping
Sketching - 3D Solidworks CAD - Manufacturing Drawings - Half-Size Physical Prototype.
Large Image - Rear of door. Top Right - Actuator. Middle Right - Hinge. Bottom Right - Latch
Prototyping - Revision 2
Lessons learnt from Revision 1
Actuator Mount Stiffening
Wiring to run through the frame
ECU housing
Removable latches for servicability
1 - Before - Sheet metal 'L-bracket' the bent during testing
1 - After - Stronger and stiffer folded and welded sheet metal profile
2 - Before - No thought given to wiring routing
2 - After - Wiring harness routed through the frame
3 - Before - No specific location for the ECU
3 - After - Fixed ECU housing
4 - Before - Welded in latches cannot be removed if damaged
4 - After - Removable cassette for servicability
CE Testing
Air Leakage Test
10'000 Open - Close Cycles
100 Open - Close Cycles at 15% under-voltage
100 Open - Close Cycles at 15% over-voltage
2 Hour Fire Test at negative 1000 pascals
100 Open - Close Cycles
Conclusion
The door passed in March 2024 - becoming the first product in the world to be CE-rated to EN12101-Part 8 - an industry changing acheievement.
The product has no competition and in coming years, it will become a UK legal requirement to have one every floor of a high-rise building.
Sales are scheduled to start in Q3 / Q4 2024
FumaCE is the far-right panel in the image - fully concealed into the wall.
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