Material Failures in Fire

Protection Systems
March 4, 2014
University of Central Florida (UCF), Orlando, FL
Jeff Pfaendtner Materials/Metallurgical Engineer
Crane Engineering Inc., Plymouth, MN

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Forensic Engineering
PROFESSIONAL DISCIPLINES
Mechanical Engineering
Metallurgical & Materials Eng.
Chemical Engineering
Electrical Engineering
Forensic Architecture
Structural Engineering
Fire Protection Engineering
Civil Engineering
Geotechnical Engineering

FORENSIC ENGINEERING & CONSULTING SERVICES

Fire and Explosion Investigation
Propane & Natural Gas Investigation
Materials & Process Engineering
Industrial Accident Investigation
Slip and Fall Investigations
Standards and Code Consulting
Building Science Investigations
Automotive System and Component Analysis
Accident Investigation and Crash Reconstruction

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Introduction
Failure Modes Relate to:
A flaw becomes a defect
when it prevents the
Design
part/system from functioning
Manufacture
as designed.
Installation
Service Environment
Water chemistry
Nominal Operating Temp & Temp extremes
Service & Maintenance
Age
Geographic location
etc.
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Case Studies
Key:
1. CPVC Spider Lines (M)
D Design
2. CPVC Environmental Stress Cracking (I&E)
M Manufacture
3. CPVC Environmental Stress Cracking (I&E)
I Installation
E Environment
4. CPVC Other Incompatible Materials (I&E)
5. Sprinkler head: Crack in Frangible Bulb (M)
6. Sprinkler head: Casting defect (M)
7. Sprinkler head: Galvanic/Crevice Corrosion (D&M)
8. Steel pipe: Microbiologically Induced Corrosion (I&E)
9. Steel pipe: Pitting Corrosion (I&E)
10. Brass Fittings: Stress Corrosion Cracking (D, M, E)
11. Steel pipe: Light wall Pipe (D)
12. Freeze failures (I & E)
13. Rube Goldberg type failures (E)
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Case 1 - Spider Lines in PVC Pipes

Straight fracture observed in CPVC pipe

after less than one year of service.
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Case 1 - Spider Lines in PVC Pipes

Outer Surface of Pipe

Scanning Electron Microscope

(SEM) images of fracture
Fracture Surface

Spider lines are virtual cracks in pipe

From manufacture process
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Case 2 CPVC & Glycol

Failure after 10 years in service.
System was a glycerin filled system, but
testing revealed the presence of glycol.

Environmental Stress Cracking (ESC) from residual glycol

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Case 3 CPVC & Alkane Oils

Wet system in condo building

Heated garage is Allied XL steel
Steel to CPVC transition (living space)
Water leaks in CPVC after ~3 years

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Case 3 CPVC & Alkane Oils

External view of
CPVC pipe
Throughthickness cracks

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Case 3 CPVC & Alkane Oils

Internal view of CPVC pipe
Multiple cracks developing on ID surface

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Case 3 CPVC & Alkane Oils

Internal view of CPVC pipe

Cracks developing around cement drip
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Case 3 CPVC & Alkane Oils

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Case 3 CPVC & Alkane Oils

Environmental Stress Cracking (ESC)

from residual thread cutting oil

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Summary: Environmental Stress Cracking

Environmental Stress Cracking (ESC) is a time dependent
(slow) cracking mechanism
ESC has three main requirements:
Susceptible material (e.g., CPVC pipe)
Stress (either residual in the material, or applied stress)
Incompatible chemical species (certain oils, plasticizers,
glycols, etc.)
Failures are usually manifested as slow leaks, but
sometimes as catastrophic breaks.

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Case 4 Incompatible Materials

CPVC potable hot water line to irrigate trash
chute in high rise condo.
Pipe failure occurred after several years in
service at location of contact with grommet.

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Case 4 Incompatible Materials

Plasticizer diffuse from one plastic into another

Pipe weakens & ruptures
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Case 5 Crack in Frangible Bulb

Sprinkler head deployed unexpectedly causing
water damage.
Purple staining observed on frame arms & body.

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Case 5 Crack in Frangible Bulb

Crack develops & propagates

Fluid leaks from bulb over time
Bulb breaks; water flows
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Case 6 Casting Defect in Sprinkler Head

200F
Attic head

Unexpected deployment of attic sprinkler head

Deformed load screw
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Case 6 Casting Defect in Sprinkler Head

SEM & X-ray imaging shows evidence of cracks in

one frame arm
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Case 6 Casting Defect in Sprinkler Head

Difference in compliance between frame arms creates

mechanical imbalance
Frangible bulb walks off set screw w/ thermal cycling
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Case 7 Galvanic/Crevice Corrosion

Sprinkler head leaked after 3 years in service.

Water damage to condo.
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Case 7 Galvanic/Crevice Corrosion

Pinhole leak in Belleville spring (under seal)

Corrosion over months/years
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Case 7 Galvanic/Crevice Corrosion

Area
A
B
C
D
E

C
3.65
9.68
7.75
9.55
7.19

O
2.06
23.53
42.56
29.86
50.96

Na

0.62

0.78

1.46
0.54

Al

Si

Cl

Ca

0.18
0.21

0.48
1.07
0.47
0.88

1.50
0.44
11.00
1.37

0.32
0.16

0.30
0.18
0.48
0.58

Ti
0.38
0.78
0.38
20.54
11.70

Mn

0.96
0.24

Scanning Electron Microscopy (SEM) with Energy

Dispersive Spectroscopy
(EDS)
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Fe
0.43
8.01
42.52
2.16
8.68

Ni
93.47
48.98
3.27
18.71
14.11

Cu

Zn

2.17

2.83
1.49
2.88
3.00

1.72
0.75

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Case 8 Microbiologically Induced Corrosion

(MIC)
Dry system developed pinhole leaks 5 years after installation.
Tubercles observed on pipe ID.
Water supply not corrosive.

High levels of aerobic bacteria,

low nutrient bacteria, and acid
producing bacteria found
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Case 9 Pitting Corrosion

A wet system developed pinhole leaks after 25 years.
Water testing showed high levels of dissolved oxygen,
high hardness, and high levels of dissolved solids.
Bacterial cultures showed low or undetectable levels
of bacteria

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Case 10 Stress Corrosion Cracking (SCC)

Catastrophic failure of brass hose valve
$1M+ water damage to large commercial
building

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Case 10 Stress Corrosion Cracking (SCC)

Catastrophic failure of brass hose valve
Multiple cracks

Raw material costs:

Copper: $3.32/lb.
Zinc:
$0.85/lb.

C37700 Forging Brass

Copper: 58.0 62.0 wt.%
Lead:
1.5 2.5 wt.%
Iron:
0.3wt% max
Other impurities: 0.5% max
Zinc:
Balance
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Case 10 Stress Corrosion Cracking (SCC)

Brass alloy defective

Zinc too high; Iron impurity too high
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Case 11 Light wall Pipe

Leaking NPT joints in

factory producing
printed circuit boards
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Case 11 Light wall Pipe

0.5mm = 0.02 inch

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2" Pipe

Case 11 Light wall Pipe

350

Schedule 40
2in. BLT

300

Linear (Schedule 40)

Linear (2in. BLT)

Torque (ft-lb)

250

R2 = 0.8983
R2 = 0.6746

200
150
100
50
0
1

# wrench turns
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Case 12 Freeze Damage

Component failure due to volumetric

expansion of freezing water (~9 vol%)
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Case 12 Freeze Damage

Freeze failures often yield multiple cracks

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Case 12 Freeze Damage

Freeze failures often yield multiple cracks

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Case 12 Freeze Damage

Freeze-up can induce large scale

deformation
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Case 12 Freeze Damage

Freeze-up can induce large scale

deformation
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Case 13 Special Environmental Effects

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Summary & Final Thoughts

All materials have their own vulnerabilities, and
therefore their own application issues.
No component is immune to failure.
A variety of failure modes are operable in fire
protection systems.
Failures can occur in all stages of life of the
system.
Failure prevention involves good system design,
material choice, good installation & maintenance
taking local environments into account
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