TECHNOLOGY AREAS: Ground/Sea Vehicles, Materials/Processes

ACQUISITION PROGRAM: PEO SHIPS – Littoral Combat Ship (PMS501) - ACAT 1D

OBJECTIVE: Develop and demonstrate a lightweight and cost effective fire insulation system to limit the spread of fire in steel or aluminum ships.

DESCRIPTION: Navy ships are currently built with steel, aluminum, or combined steel and aluminum construction. One of the many design considerations for steel or aluminum is fire performance. The US Navy fire safety goals for surface ships include limiting fire spread (fire resistance), preventing flashover (fire growth), and maintaining tenability (smoke and fire gas toxicity). Recent and past work performed by the US Navy indicates that current US Navy steel or aluminum designs do not meet the fire safety criteria without passive fire protection systems. Passive fire protection is used aboard US Navy ships to contain fire and prevent fire spread to adjacent or overhead compartments. For fire resistance, the performance criteria is 30 minute or more rating with backside peak temperature rise less than 325°F and average temperature rise less than 250°F (UL-1709 fire curve). The test procedures are in accordance with MIL-PRF-32161 (reference 1).

The Navy currently uses high temperature alkaline earth silicate fiber batt, which is installed with steel pins and caps to meet shock requirements prior to fire resistance tests. It weights approximately 7-8 lbs/ft3. For a N-30 rating (30 minute rating using UL 1709 fire curve during a fire resistance test) where insulation is attached on both sides, the fiber batt system weighs approximately 1.68 lbs/ft2. Due to a combination of factors such as weight, attachment system complexity, material and labor costs, there is a need for a more cost-effective lightweight fire insulation system.

Technical issues to be addressed include application and attachment of insulation products to the substrate and the effectiveness of insulation products in meeting fire resistance tests. The insulation products should be cost effective and possess general and physical properties compatible with shipboard environment such as weight, adhesion, salt spray, impact, shock, etc. All passive fire protection materials shall meet the requirements of MIL-PRF-32161, Type 1.

PHASE I: Demonstrate the feasibility of a low-cost, light-weight passive fire protection solution. Evaluate solutions in the form of materials, passive fire protection concepts, and production/installation methods to exceed performance of current Navy methods as measured by weight, cost, and performance (fire growth, tenability, fire resistance, fire endurance). Establish performance metrics to analyze the feasibility of the proposed solution. Develop a test and evaluation plan that contains discrete milestone for product development for verifying performance and suitability.

PHASE II: Develop and demonstrate prototype materials/methods based on Phase I results. In a laboratory environment, demonstrate that the prototype(s) meet the performance goals established in Phase I. Demonstrate installation, maintenance and removal methodologies. Provide detailed production/installation plans and estimates, production drawings, logistic support plans, weight breakdown, and system cost estimates (both acquisition and lifecycle).

PHASE III: Working with the Navy, develop transition plans and demonstrate the commercial and shipboard uses of the lightweight low-cost fire barrier. Coordinate with the Navy to develop and execute plans for shipboard installation in a suitable application in conjunction with a Navy ship acquisition program.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Steel and aluminum construction are used in the commercial marine shipbuilding, offshore platforms, and aircraft industries where improved fire safety is of high interest. Development of a fire barrier with superior cost, weight, and performance characteristics will directly benefit the US Coast Guard and civilian shipbuilding industry.

REFERENCES:
1. "Performance Specification Insulation, High Temperature Fire Protection, Thermal and Acoustic," MIL-PRF-32161. http://assist.daps.dla.mil/quicksearch/
Available at http://www.navysbir.com/ via the SBIR/STTR Interactive Topic Information System (SITIS) web link
2. ABS Naval Vessel Rules, Section 1-2-1, Structural Fire Protection.
3. Evaluation of Intumescent Coatings for Shipboard Fire Protection; U. Sorathia, T. Gracik, J. Ness, A. Durkin, F. Williams, M. Hunstad, F. Berry (submitted for publication in Journal of Fire Science).

KEYWORDS: Insulation; Lightweight; Fire Resistance; Fire Protection;

TPOC: Mr. Usman Sorathia
Phone: 301-227-5588
Fax: 301-227-4814
Email: [email protected]
2nd TPOC: Mr. David Satterfield
Phone: 202-781-3647
Fax:
Email: [email protected]

** TOPIC AUTHOR (TPOC) **

DoD Notice:   Between May 1, 2006 and June 13, 2006, you may talk directly with the Topic Author(s) to ask technical questions about the topics. Their contact information is listed above. For reasons of competitive fairness, direct communication between proposers and topic authors is not allowed starting June 14, 2006 , when DoD begins accepting proposals for this solicitation.

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