1. Designing scientific
facilities for flexibility
and high chemical
loading while
maintaining
compliance with fire
codes
Kim Jeskie, MPH-OSHM
Operations Manager
Doug Freels
Fire Protection Engineering
Physical Sciences Directorate
Oak Ridge National Laboratory
2. 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 Code
Companion Fire Code, and
Applicable NFPA Codes and Standards
Note: Plan and design for your chemical inventories…..
2 Managed by UT-Battelle
for the U.S. Department of Energy
3. 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)
4 Managed by UT-Battelle
for the U.S. Department of Energy
4. 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….
5 Managed by UT-Battelle
for the U.S. Department of Energy
5. Maximum Allowable Quantity
IBC Assumes Sprinkler Protection Provided
Quantities May be Doubled If In Cabinets
2003 International Building Code Number of Haz
Reference Table 414.2.2 Mat Control Flammable Liquid Flammable Gas
Areas Per Class IA 60 gal 2000 cubic feet
Floor
Fourth Floor 7.5 gallons 250 cubic feet
2 HMCAs
12.5% of MAQ ~1 cylinder
2 HMCAs
Third Floor 30 gallons 1000 cubic feet
50% of MAQ ~4 cylinders
Second Floor 45 gallons 1500 cubic feet
3 HMCAs
~6 cylinders
75% of MAQ
4 HMCAs
First Floor 60 gallons 2000 cubic feet
~8 cylinders
100% of MAQ
Basement 1500 cubic feet
Not Permitted
3 HMCAs ~6 cylinders
Contact FPE
75% of MAQ
6 Managed by UT-Battelle
for the U.S. Department of Energy
6. Effect of Infrastructure on Maximum
Allowable Quantities
4500N: Constructed to 1950’s Standards
Status
• Inadequate configuration control and Examples of MAQs for Chem Control Area
qualified maintenance of fire barriers. Flammable Gases
• Single approved chemical control area 1,500 ft3 (~6 full cylinders); could double if in
(CCA) for entire building approved cabinets
• 4500N contains several synthetic chemistry Current inventory lists 10,500 ft3 in building (~42
laboratories 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.
7 Managed by UT-Battelle CCA = Approved Fire Rated
for the U.S. Department of Energy CCA, not HMIS Area
7. Effect of Infrastructure on Maximum
Allowable Quantities
8600, CNMS: Constructed to 1999 SBC
Status
• New construction. Fire barriers in place and Examples of MAQs for Chem Control Area
maintained Flammable Gases
• 10 CCAs, plus higher hazard occupancy storage 1,500 ft3 (~6 full cylinders) for each CCA; could be
areas doubled if in approved cabinets
• Contains synthetic chemistry labs, clean room Remember this is for 1 CCA. The building has 10. Two-
and instrument labs lab modules in some cases equal 1 CCA.
Higher hazard bays for chemical storage. Limited only
by physical storage space and compatibility
Highly 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.
8 Managed by UT-Battelle
for the U.S. Department of Energy
8. What are Building/Fire Code Limits?
My Definition: The code limit for chemicals / hazardous materials for the corresponding safety envelop
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 Learned
a) 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.
9 Managed by UT-Battelle
for the U.S. Department of Energy
9. Selected Elements of a Design
Solution/Safety Envelope: Guided by R&D
“Needs” and Code Requirements
Occupancy classification Fire department standpipe connections
e.g. Business with labs and Group H areas
Portable fire extinguishers
per I-Codes and Labs/Industrial per NFPA
1, 45, and 101 1500 KW Generator-backed emergency
Size/Area Limitations lights and exit signs
Noncombustible/fire-rated construction Generator-backed lab exhaust
Fire detection and alarm system Lightning protection
Means of Egress/Exit Routes compliant Fire-rated and configurable hazardous
with Life Safety Code materials control areas (HMCAs)/Laboratory
Units
Complete automatic wet-pipe
sprinkler protection Strategically located and separated
hazardous materials storage rooms
Fire department/emergency
response access Exterior cylinder storage area(s)
10 Managed by UT-Battelle
for the U.S. Department of Energy
10. 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)
11 Managed by UT-Battelle
for the U.S. Department of Energy
11. Research Needs Drove an Innovative Design that
Mitigates Risk and Enhances Team-Based Science
Flexible Space
Research
Community
• Service corridor for transfer of hazardous • Filtered exhaust where needed
materials away from office areas • Flexible space available to accommodate
• Higher hazard storage areas mission growth
available on each floor • Co-location of sample preparation,
• Increased visibility into labs material synthesis, and characterization
• Co-location of theorists, students,
• Suites of labs that can be easily
and support staff
isolated and secured
12 Managed by UT-Battelle
for the U.S. Department of Energy
12. Hazardous Materials Management needs to
be a Cornerstone of the Design Solution
• Laboratory communities designed • Hazardous materials storage areas
to accommodate flexible hazardous will enable:
materials control areas – Life cycle management model
• Vented enclosures and house manifolds – Chemical “stores” and reuse
provided to minimize cylinder use
and control quantities
13 Managed by UT-Battelle
for the U.S. Department of Energy
13. Initial Configuration of the First Floor Hazardous Materials
Control Zones / Lab Units:
XYZ
14 Managed by UT-Battelle Building XYZ
for the U.S. Department of Energy
