Building codes new building

Designing scientific facilities for flexibility and high chemical loading while maintaining compliance with fire codes Kim Jeskie, MPH-OSHMOperations Manager

Doug FreelsFire Protection Engineering

Physical Sciences DirectorateOak Ridge National Laboratory

2 Managed by UT-Battellefor the U.S. Department of Energy

Background: Since 1997 ORNL has built more than 30 “new” facilities with more than 1.6 million sq.ft.

Chemical limits are clearly defined in the Code(s) of Record including the:

Building CodeCompanion Fire Code, and Applicable NFPA Codes and Standards

Note: Plan and design for your chemical inventories…..


Code Development related to Hazardous Materials/Chemicals

• Pre-1980’s very few requirements– NFPA regulated specific materials (flammable liquids,

oxidizers, organic peroxides)– Model building/fire codes limited few materials, primarily

flammable & combustible liquids • Mid-1980’s events initiate code changes

– Toxic gas (methyl isocyanate) release killed thousands in Bhopal, India (1984)

– Semiconductor industry with first regulation of “health hazard” chemicals (1985)


Code Development related to Hazardous Material, cont.• 1988 Uniform Fire and Building Codes

– Established a “new model codes” comprehensive approach to regulating storage and use of common hazardous materials.

– Developed “exempt” amounts and control area concept• 1994-2000 Other national codes join in

– The three model code organizations formed a single set of codes (IBC/IFC) for hazardous material limits and controls

• 2000-2003 NFPA expanded – NFPA develops building code and re-writes fire code to

establish hazardous material limits• 2006-Present: MAQs (limits) in Building Codes and Fire Codes /

Standards becoming increasingly similar….


3 HMCAs

4 HMCAs

3 HMCAs

2 HMCAs

2 HMCAs

Maximum Allowable QuantityAssumes Sprinkler Protection Provided

Quantities May be Doubled If In Cabinets

7.5 gallons

30 gallons

45 gallons

60 gallons

Not PermittedContact FPE

IBCFlammable LiquidClass IA 60 gal

Flammable Gas2000 cubic feet

2000 cubic feet~8 cylinders


250 cubic feet~1 cylinder



Number of Haz Mat Control Areas Per

Floor

2003 International Building CodeReference Table 414.2.2

First Floor

100% of MAQ

Second Floor

75% of MAQ

Third Floor

50% of MAQ

Fourth Floor

12.5% of MAQ

Basement

75% of MAQ


Effect of Infrastructure on Maximum Allowable Quantities 4500N: Constructed to 1950’s StandardsStatus• Inadequate configuration control and

qualified maintenance of fire barriers.• Single approved chemical control area

(CCA) for entire building• 4500N contains several synthetic chemistry

laboratories

Examples of MAQs for Chem Control AreaFlammable Gases· 1,500 ft3 (~6 full cylinders); could double if in

approved cabinets· Current inventory lists 10,500 ft3 in building (~42

cylinders, 1 per lab)Highly Toxic Liquids· 2 lbs; could double if in approved storage cabinets· Current report lists 512 lb in building· Formaldehyde: one 500 mL bottle equates to 1.2 lb

Renovation of Wing 4· Would have created 4 additional CCAs for that area

alone. Essentially, multiplying the above limits by 4.· Design Plan created 2 additional areas within the wing

where unlimited quantities of highly toxic liquids and/or much greater quantities of flammable gases could be stored.

CCA = Approved Fire Rated CCA, not HMIS Area


Effect of Infrastructure on Maximum Allowable Quantities8600, CNMS: Constructed to 1999 SBCStatus• New construction. Fire barriers in place and

maintained• 10 CCAs, plus higher hazard occupancy storage

areas• Contains synthetic chemistry labs, clean room

and instrument labs

Examples of MAQs for Chem Control AreaFlammable Gases· 1,500 ft3 (~6 full cylinders) for each CCA; could be

doubled if in approved cabinets· Remember this is for 1 CCA. The building has 10. Two-

lab modules in some cases equal 1 CCA.· Higher hazard bays for chemical storage. Limited only

by physical storage space and compatibilityHighly Toxic Liquids· 2 lbs; could double if in approved storage cabinets· Example: one 500 mL bottle of formaldehyde equates to

1.2 lb· 8600 inventory in HMIS, but not linked to FUA report.

Limits in RSSs and enforced through a combination of purchase reviews and assessment.


What are Building/Fire Code Limits?

1. Building Use/Activities Determines Occupancy Classification i.e. Business, Industrial, Factory, Hazardous, Assembly, Mixed, etc.

2. Each Occupancy Classification has associated protective features (safety envelope) and code-prescribed chemical limits

Purpose…is to prescribe minimum requirements necessary to establish a reasonable level of fire and life safety and property protection from the hazards created by fire, explosions, and dangerous conditions.

3. Code-Of-Record Design Solution and/or Requirements (limits) from Operational Codes

A. Design of The Structure/System (code of record)1) Building Code….prescribes chemical limits

B. Operational Requirements (things change)1) Updated Operational Codes/Standards..…also prescribes chemical limits based on occupancy,

protective features, etc……Lessons Learneda) The IFC or NFPA 1 Fire Code, NFPA 45, NFPA 55, etc.

Discuss Code Of Record and Applicability Examples: Asbestos, PCBs, Lead, Hazardous Materials, etc.

My Definition: The code limit for chemicals / hazardous materials for the corresponding safety envelop


Selected Elements of a Design Solution/Safety Envelope: Guided by R&D “Needs” and Code Requirements

Occupancy classification

e.g. Business with labs and Group H areas per I-Codes and Labs/Industrial per NFPA 1, 45, and 101

Size/Area Limitations

Noncombustible/fire-rated construction

Fire detection and alarm system

Means of Egress/Exit Routes compliant with Life Safety Code

Complete automatic wet-pipe sprinkler protection

Fire department/emergency response access

Fire department standpipe connections

Portable fire extinguishers

1500 KW Generator-backed emergency lights and exit signs

Generator-backed lab exhaust

Lightning protection

Fire-rated and configurable hazardous materials control areas (HMCAs)/Laboratory Units

Strategically located and separated hazardous materials storage rooms

Exterior cylinder storage area(s)

- EXAMPLE -


The Roadmap: Things To Know/Do to Manage Chemical Inventory Limits• What Chemicals/Hazardous Materials do we have/use?

– MSDS, etc….characterization….• Physical Hazards (e.g. combustibles, flammables, oxidizers, reactives, etc.) • Health Hazards (e.g. corrosives, toxic, highly toxic)

• Where are we using/storing the chemicals?– Be Specific….which Facility/Room/Lab?– “Map” inventories to your 1-hour fire-rated control areas

• How Much? – Quantities (solids, liquids, gases) of each chemical in each location

• What are the Limit(s) for a given Facility/Room/Lab• For Solids, Liquids, and Gases (Building/Fire/NFPA Codes & Standards)• Take Credit for Protection features/levels (Sprinklers?, approved cabinets?, etc.)

• Compare and Evaluate the Inventory against the Limit(s)• Operate within the Limits or risk-manage the delta(s)


Research Needs Drove an Innovative Design that Mitigates Risk and Enhances Team-Based Science

Research Community

Flexible Space

• Service corridor for transfer of hazardous materials away from office areas

• Higher hazard storage areas available on each floor

• Increased visibility into labs• Suites of labs that can be easily

isolated and secured

• Filtered exhaust where needed• Flexible space available to accommodate

mission growth• Co-location of sample preparation,

material synthesis, and characterization• Co-location of theorists, students,

and support staff


Hazardous Materials Management needs to be a Cornerstone of the Design Solution

• Laboratory communities designed to accommodate flexible hazardous materials control areas

• Vented enclosures and house manifolds provided to minimize cylinder use and control quantities

• Hazardous materials storage areas will enable:

– Life cycle management model– Chemical “stores” and reuse


Initial Configuration of the First Floor Hazardous Materials Control Zones / Lab Units:

XYZ

Building XYZ


Fire Barrier Integrity/1-hour HMCAs


Sprinkler Protection/Exhausted Enclosures/Approved Cabinets


Ventilated Gas Cabinets


Ventilated Gas Cabinets, cont.

19 Managed by UT-Battellefor the U.S. Department of Energy EFCOG_March2012_Jeskie

Summary and questions

Kim [email protected]

Building codes new building

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