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SAFE CABLING SYSTEMS IN TUNNELS UNDER FIRE

Urs Welte
Amstein + Walthert AG, Switzerland

ABSTRACT
The paper aims at a detailed analysis of the current know-how in the construction of tunnel
cabling systems and shows the impact of fire and heat and the respective measures to be
taken. Therefore the results of the test projects EUREKA Firetun and MEMORIAL are
scrutinized and evaluated in view of the today's boundary conditions in typical cross sections.
It will clearly be shown how the heat distribution is dependant on the cross section and the
ventilation system.
Further it will be shown how concrete will protect cables from heat and damage even if the
coverage is low and how far open mounted installation channels are endangered.
For typical cabling systems it shall be outlined which requirements and specifications
regarding fire and heat resistance are reasonable and required. A short discussion of the
applicable norms and standards shall provide further information and decision guidance. It
shall be clarified that high safety standards re isolation and fire resistance are not generally
required.

1. CABLES IN THE TUNNEL

Cables are accommodated in road tunnels at different places: in lower floor panel troughing
systems, containing tubing blocks and pits, on routes at the tunnel cover (lighting,
communication, fire protection), on routes behind the wall lining, as well as in pits, ascents,
air ducts, traversing and in accessible cable tunnels.
lamp fire sensor cable
cable channel

radio cable ceiling tube

exhaust air ventilator

fresh air

wall ascent

signal

wall ascent

fire emergency
lighting

tubing block

tubing block

cable duct transfer tubing block LED-lighting

cable duct

Fig. 1: Cabling systems in typical cross section

The different fire hazard of the cable systems can be judged due to the heat distribution in the
case of fire.

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2. FIRE IN THE TUNNEL

A fire event in a tunnel is often combined with a rapid temperature rise, connected with a fast
propagation of smoke gases. The fire scenario depends on most diverse factors, which are
substantial:
• fire load: Passenger vehicles, bus, truck with/without charge
• ventilation system of the tunnel
• air flow conditions at the beginning of the fire
The fire load can reach very high values, in particular if several vehicles are involved. It
starts for individual vehicles at 5 MW (passenger vehicle) over 20 MW (bus) up to 100MW
(truck). Additionally the air flow (partially affected by the mechanical ventilation) has an
impact on the propagation of the hot combustible gases in the tunnel.

3. STANDARD FIRE CURVES

In order to have a uniform basis for technical calculations as well as for practical tests, the
temperature gradient is defined by so-called standard fire curves.

d
c
Temperature [°C]

c e
d
e
f

Fire duration [min]

Fig. 2: Standard fire curves

The most common standard fire curve is the ISO standard 834. It forms the basis for the
examination of buildings and construction units. The examination of cable systems (cables
inclusive fittings and laying systems) is described in the DIN 4102-12 and led to the well-
known inspection certificates like e.g. "E30" (function during 30 minutes). However, the ISO
standard was developed for above ground structures - not for tunnels -, and has therefore only
limited relevance for this special field. Therefore, also the curve of the Netherlands authorities
(Rijkswaterstaat) is used, the so-called RWS-curve. The temperatures reach in accordance
with this fire curve over 1300 degrees after approximately 50 minutes. However, this curve is
internationally not recognized.

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4. FIRE TESTS
Some time ago two series of fire tests in tunnels were executed. The results thereof are often
consulted for the evaluation of fire risks.

c Truck
d Bus
e Car
Temperature [°C]

d
e

Distance to fire [m]

Fig. 3: Maximum temperatures at the ceiling (EUREKA-Project 499 Firetun)

The tests showed very high roof temperatures over the fire source, which were reached after a
short time of only 20 minutes. However, the tunnels had a cross-section area of 30 m2 only.
This corresponds with about the half of a modern road tunnel with two driving lanes.

5. MEMORIAL TEST USA 1993

The American Memorial tunnel has a 60 m2 cross section and is similar to the Swiss standard;
thanks to ventilation systems also the simulation of air flows were possible.

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Fig. 4: Memorial Tunnel Fire Ventilation Test Program: 10 minutes after fire start,
20 MW-fire

Fig. 5: Memorial Tunnel Fire Ventilation Test Program: 10 minutes after fire start,
50 MW-fire

The comparison with EUREKA shows that with attention of the flow effect and the cross
section many lower temperatures are measured. Further, the higher temperatures were
measured with relatively high fire loads only.

6. WHICH TEMPERATURES HAVE TO BE EXPECTED?

A critical comparison of the fire curves and the test series leads to the clear result that the
temperatures reach generally neither the values of the standardized fire curves, nor those of
the EUREKA tests. Very close to the Swiss conditions are the MEMORIAL tests. The
Memorial tunnel tests showed clearly that with an efficient smoke exhaust close to the fire
source the temperature and smoke propagation can be reduced considerably (in accordance
with the new Swiss guidelines for the project engineering of road tunnels the ventilation
system must offer the possibility of a local smoke exhaust). The following illustration shows
the temperatures which can be expected.

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no temperature change ≤ 50 °C

small temperature change 50 – 150 °C

high temperature change ≥ 150 °C

Fig. 6: Temperature zones during fire

7. CABLE UNDER FIRE: STANDARDS

For cable systems the behaviour in case of fire (passive characteristics) as well as the fire
resistance (active characteristics) are important to consider. In order to define the appropriate
safety level, the standardization situation has to be regarded more closely.

Properties International Europe

flame retardant IEC 60332-1 EN 50265-2-1
halogen free IEC 60754-1 EN 50267-2-1
no corrosive gases IEC 60754-2 EN 50267-2-3
low smoke emission IEC 61034 EN 50268
low flame propagation IEC 60332-3-24 EN 50266-2-4
Fig. 7: Applicable standards for behaviour in case of fire

For the active characteristics of cables the following standards are relevant. They define the
requirements during fire.

Properties International Switzerland

Circuit integrity
- Fire only IEC 60331 --
- Voltage (<1kV)
- Data cable
- Fibre optic cable
Fig. 8: Applicable standards for circuit integrity

The system circuit integrity of cable systems is mostly the most important issue. Thus the
system function can be guaranteed during fires for a certain period. In the extensive
standardization work DIN 4102 the system circuit integrity is treated for electrical cable
systems in the part 12. The standard comprises the entire cabling system, i.e. cable inclusive
carrying system. However, it is applicable only to low-voltage cables (< 1 kV), thus not to
high-voltage cables and also not to fibre optic cables. System circuit integrity classes are
defined (in minutes): E30, E60, E90.
Furthermore, the requirements can be divided in three groups:

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Halogen free
Require- Circuit Circuit
and flame
ments Requirements IEC-Standard integrity integrity
retardant
Group (≥ FE 5) (E30 - E90)
cables (FE 0)
Function Circuit integrity DIN 4102-12 -- -- X
Isolation Circuit integrity IEC 60331-11 -- -- X
Material flame retardant IEC 60332-1 X X X
halogen free IEC 60754-1 X X X
no corrosive gases IEC 60754-2 X X X
low smoke emission IEC 61034 X X X
low flame propagation IEC 60332-3-24 -- X X

Fig. 9: Requirements groups

8. RECOMMENDED CABLE SAFETY CLASS

Safety cable systems cause extra costs; it is therefore worthwhile to regard conditions:
Basic Requirements Higher Requirements Additional cost
cables: 1.5 mm2 16 mm2
FE 0 FE 180 (E 30) 60 - 100% 30 - 50%
FE 5 FE 180 (E 30) 20 - 40% 10 - 20%
FE 180 E 30 0% 0%
Installation material
no fire protection E 30 60 - 100%
Cable trough
Material: without fire protection E 30 60 - 100%
Installation: without fire protection E 30 20 - 30%

Fig. 10: Additional cost for circuit integrity cables

In which cases are these extra costs justified? Generally, halogen-free and flame-retardant
cables are mandatory for a tunnel. Also safety cables, which offer a protection against the
consequences and the propagation of a fire. Safety cables with system circuit integrity are
recommended if temperature and availability risk are relevant, e.g. installation cables in the
tunnel cross section: Lighting, ventilation, signing. Cable systems in tubing blocks or in pipes
with sufficient concrete cover (> 10 cm) usually require no system circuit integrity, since they
are sufficiently protected by their specific situation. Safety relevant cables have to be
considered especially, e.g. cables for uninterrupted power supplies (UPS): They should at
least have the same system circuit integrity as the overall system they belong to.

9. CONCLUDING REMARK
Fire accidents in road tunnels result often in high temperatures due to the limited cross
section. The temperatures indicated in the standards always describe the values maximally
arising during a fire event; however, these values have to be expected only within the upper
tunnel area. At the lower level the temperatures are significantly lower. Due to safety
considerations, the general demand for system circuit integrity cannot be justified for cable
systems in accordance with DIN 4101-12, since the risk reduction is only marginal in many
cases. However, each project must separately be regarded due to the object-specific
conditions.

3rd International Conference ‘Tunnel Safety and Ventilation’ 2006, Graz