Workshop on

Bus Technologies and Bus Code Type Approval

AIS 052:AUTOMOTIVE INDUSTRY STANDARDS

CODE OF PRACTICE FOR BUS BODY DESIGN AND APPROVAL

Flammability Testing Requirements

M A Bawase
Automotive Materials Laboratory

November 04, 2015

THE AUTOMOTIVE RESEARCH ASSOCIATION OF INDIA, PUNE

Need for Flammability Testing
o Use of Polymeric Materials in Vehicles…
 For weight reduction and Fuel Efficiency of vehicles the trend is to
replace metallic components by polymeric components.
 Polymers are used to give ride comfort and aesthetic looks to the
vehicles.
 Ease of processibility, availability and lower cost of polymers
o Why Flammability Assessment of Polymers …
 Use of polymer in automobiles is rising.
 Polymer is vulnerable to catch fire.
 Hence for occupant’s safety and for opportunity to escape in
case of vehicle fire, these materials are required to test for
flammability characteristics.
Flammability Testing Requirements
as per AIS 052

Flammability Testing

Electrical
Conductor Test IS 15061

Annex. A
Horizontal Burning Rate

Annex. B
Vertical Burning Rate

Annex. C
Melt Behaviour Test
Electrical conductor test — Chapter 6 clause 6.8
FLAMMABILITY REQUIREMENTS
 Electrical conductor test as per AIS 052 Chapter
6 clause 6.8
1. Principle :
This test consists of submitting specified test pieces of the electrical
conductors, as installed in the vehicle, to a flame in order to evaluate their
resistance to fire.
2. Classification as per clause 6.8.6.1:
Based on the results obtained, the material will be classified as follows:
Category 1: Combustion is self- extinguished.
The upper end of the test piece is intact.
Category 2: Combustion is self- extinguished.
The upper end of the test piece is charred or affected.
Category 3: Combustion is not self-extinguished.

3. Acceptance Criteria as per 6.8.7

Only Category 1 conductors are permitted.
 Electrical conductor test as per AIS 052
Chapter 6 clause 6.8
Test Summary:

1. 600mm œ25mm long test piece of conductor is

vertically mounted in middle of test enclosure.
2. The heat source consists of a gas burner having
the outer flame approximately 125 mm and that of
the inner flame approximately 40 mm is applied
about 100 mm above the lower end of the test
piece for continuous period T (Seconds) as
T= 60 + M/25
where M is mass of 600mm length conductor
3. Observation to be reported:
- the duration of the combustion
- the length of the charred section.

Electrical Conductor test

 IS 15061
AUTOMOTIVE VEHICLES —
FLAMMABILITY REQUIREMENTS
 IS 15061: AUTOMOTIVE VEHICLES — FLAMMABILITY REQUIREMENTS
Materials and Test Applicability

Melt Behaviour
Vertical Burning Rate
• Fabric, Foam, • Hanging Materials • Interior lining of the
Horizontal Burning Rate

like roof,
• Seat belt,
• Curtains, • luggage racks,
• Plywood, ABS, FRP,
• Blinds, • Heating and
• PVC Flooring,
• Sunvisor, ventilation pipes
• Child safety restraint system, situated in roof ,
• Handles, etc
• Roof lining, • luminaries situated in
• Convertible top, luggage racks and/ or
• Armrest trim, roof
• Front trim, Rear trim, Side trim,
• Rear package tray,
• Head restraint Carpe,
• Mat,
• Sunvisor, Sunshade,
• Wheel—house liner,
• Engine compartment cover,
• Mattress cover,
• Instrument panel pad,
• Steering center pad,
• Air bag,
• Knee bolster,
• leather, etc.
 AUTOMOTIVE VEHICLES — FLAMMABILITY REQUIREMENTS

1. IS 15061: ANNEX A : HORIZONTAL BURNING RATE

Horizontal Flammability Tester

Samples to be tested Fabric, Foam, Seat belt, Plywood, ABS, FRP, PVC
as per Annex A- Flooring, Child safety restraint system, Roof lining,
Horizontal Flammability Convertible top, Armrest trim, Front trim, Rear trim,
Side trim, Rear package tray, Head restraint Carpe,
Mat, Sunvisor, Sunshade, Wheel—house liner,
Engine compartment cover, Mattress cover,
Instrument panel pad, Steering center pad, Air bag,
Knee bolster, leather, etc.
1. IS 15061: ANNEX A : HORIZONTAL BURNING RATE

Test specimen of dimension 356 mm X 100 mm X thickness 13 mm max is placed

horizontally in chamber and Flame is applied at one edge of specimen for period
of 15 seconds and burn rate is calculated based on travelling of flame from point
marked at A (38mm) to point marked at B (292 mm).

Typical Photograph - Before Test Typical Photograph - After Test

𝐵𝐵𝐵𝐵𝐵 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷, 𝑖𝑖 𝑚𝑚
𝐵𝐵𝐵𝐵𝐵𝐵𝐵 𝑟𝑟𝑟𝑟, 𝑚𝑚/ min = 𝑋 60
𝑇𝑇𝑇𝑇 𝑖𝑖 𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑓𝑓𝑓 𝑏𝑏𝑏𝑏𝑏 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑

Testing Requirements:
The horizontal burning rate shall not exceed 100 mm/min OR
if the flame extinguishes before reaching the last measuring point.
2. IS 15061: ANNEX B : VERTICAL BURNING RATE

Samples to be tested Hanging Materials like Curtains, Blinds, Sunvisor,

as per Annex B- Handles, etc.
Vertical Flammability

Test Procedure:
Test specimen of dimension 560 mm X 170 mm is placed vertically in
chamber and Flame is applied at one edge of specimen for period of
15 seconds and burn rate is calculated based on measurement of
travelling of flame with distance
1. V1 = Point marked at A (20 mm) to point marked at B (240 mm).
2. V2 = Point marked at B (240 mm) to point marked at C (390 mm).
3. V3 = Point marked at C (390 mm) to point marked at D (540 mm)
2. IS 15061: ANNEX B : VERTICAL BURNING RATE

Calculation:

}
𝑑𝑑
1. V1 = x 60 Highest burn rate
𝑡𝑡
𝑑2 amongst 3 shall not
2. V2 = x 60 exceed 100 mm/min
𝑡2
𝑑2
3. V3 = x 60
𝑡2

Typical Photograph Typical Photograph

Before Test After Test

Testing Requirements:
The Vertical burning rate shall not exceed 100 mm/min taking the worst
test result into account.
3. IS 15061: ANNEX C : MELTING BEHAVIOUR

Samples to be tested as Interior lining of the roof, luggage racks, heating and
per Annex C – Melting ventilation pipes situated in roof or luminaries
Behaviour situated in luggage racks and/ or roof

Test Procedure:
• 70 mm X 70 mm test specimen is placed under source of heat is an
electric radiator with a useful output of 500 W at distance of 30 mm for
period of 5 minutes.
• Within period of 5 minutes, test specimen shall not form a drop after
melting which ignites cotton placed beneath at distance of 300 mm.
3. IS 15061: ANNEX C : MELTING BEHAVIOUR

Typical Photograph Typical Photograph

Before Test After Test
Melting BehaviourTester

Testing Requirements: No drop shall formed which ignites the cotton wool
Automotive Materials Laboratory at ARAI is
capable of taking up below referred test work under
one roof and has wide experience of more than 15
years and expertise in this field. Besides above test
facility for flammability of automotive materials, the
laboratory is well equipped for flammability tests as
per FMVSS 302, ISO 3795, UL 94, ASTM D 635, IS
7888 and OEM’s test standards.

Thank You