Technical Article

High Expansion Foam Systems

Martin Workman
Viking Product Manager

September, 2008

Worldwide Fire Protection www.vikinggroupinc.com

 High Expansion Foam Systems

TABLE OF CONTENTS

INTRODUCTION 3
SYSTEM DESIGN 5
SYSTEM COMMISSIONING 7
CONCLUSION 8

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High Expansion Foam Systems

INTRODUCTION

High Expansion foam systems are installed in many different hazards; high piled storage, liquefied
natural gas, dike or bund protection, aircraft hangars, etc.

What is a high expansion foam system? A high expansion foam system is a foam deluge system
that delivers the foam solution, (foam concentrate and water mixture), to a discharge device known as a
high expansion foam generator.

Figure 1: Foam Deluge Riser – Photo Courtesy of S&L Mechanical

Most commercially available foam generators are water powered fans that force or “blow” the foam
solution against a screen which results in a finished foam blanket that expands into a large fluffy cloud of
foam bubbles. If you ever blew bubbles as a child, you submerged the circular ring dipping wand into a
soapy solution, as you blew air through the circular end of the wand where the soapy film clung to, large
bubbles would result on the discharge side of the dipping wand. High expansion foam generators work
in essentially the same way, with the obvious exception being that the quantity of the soapy solution is
greater, more air is provided, and the screen has thousands of more holes than the dipping wand.

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 High Expansion Foam Systems

Figure 2: High Expansion Foam Generators – Photo Courtesy of Chemguard

High expansion foam generators are “open discharge” devices, meaning there is not a fusible
link, like in an automatic sprinkler head. The piping supplying the foam generator is empty, until a deluge
valve is activated. When the deluge valve is activated, water passes through the riser past a proportioning
device, which is located in line with the sprinkler piping. The proportioning device is where the foam con-
centrate is introduced into the water stream to form a foam solution. Foam solution leaves the proportioning
device and travels down the empty piping until it enters the foam generator. Think of the foam generator as
a water motor alarm, the foam solution pushes the fan in a circular motion, the foam solution discharges
through a nozzle or series of nozzles, (depending upon the manufacturer), and the air current provided
by the fan pushes or forces the foam solution against a screen, which in turn creates the large bubbles. I
made the comparison to the water motor alarm, as they operate in a similar fashion and they both need
to have strainers installed on the supply piping prior to connecting to the devices. Some manufacturers
include this strainer, others do not, but in all cases, consult the manufacturer for the correct strainer, as the
strainer mesh will vary depending upon the integral discharge nozzle(s) orifices of the foam generator.

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High Expansion Foam Systems

SYSTEM DESIGN

We normally think of sprinkler systems in two dimensional terms, we look down from the ceiling on
our drawings in the plan view, our system design water flow rate is generally referred to in terms density,
which is gallons per minute per square foot.

High expansion foam system design is a three dimensional thought process. NFPA utilizes a foam
submergence volume as a rate of application. Most designs are based upon 3 cubic feet per square foot
per minute. High expansion foam fills a space with a puffy foam blanket. Care should be taken to note
where wall openings may occur. If doors are present, they must be self closing doors as the effectiveness
of the high expansion foam is based on the foam blanket staying in the hazard. If wall openings are present
and un-avoidable, additional high expansion foam must be provided to account for the “leakage” of the
medium from the hazard area.

Figure 3: High Expansion Foam Discharge – Photo Courtesy of Chemguard

A handful of NFPA standards discuss the use of high expansion foam as a protection option.
Chapter 6 of NFPA 11, The Standard for Low, Medium, and High Expansion Foam lays out the basic guide-
lines for the installation of a high expansion foam system. Early in the chapter it explains what hazards it
can be used for and what hazards it cannot be used for. High expansion foam can be used for ordinary
combustibles (Class A Fires), Flammable and Combustible Liquids (Class B Fires), and a mixture of Class
A materials and Class B materials, and liquefied natural gas. Caution should be exercised when protecting

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 High Expansion Foam Systems

combustible and flammable liquids, if the liquid is miscible, contact the high expansion foam manufacturer
to determine if their high expansion foam is suitable for the miscible liquid. High expansion foam shouldn’t
be used where there are water reactive materials or metals, chemicals that release sufficient oxygen to
sustain combustion, or liquefied flammable gas.

NFPA 11 also discusses personnel safety in the use of high expansion foam. Once the system
activates, the area fills with a foam blanket, if personnel are located in the hazard at the time, they are
essentially blinded by the foam blanket. Adequate pre-operation alarms must be present to prevent some-
one from being trapped in the hazard area. If you are to enter a space where a high expansion foam
discharge has occurred, you are to use a hose stream to break down the foam or to cut your way through
the foam. Generally a fire hose with a fog nozzle will do the job. One should never enter a high expansion
foam blanket without some sort of life line and a breathing apparatus, the best way to enter a high expan-
sion discharge is cutting your way through it with a hose stream.

NFPA also provides guidance regarding how deep the high expansion foam has to build to. The
depth requirement is as follows: 1.1 times higher than the highest hazard but in no case less than 2 ft. over
the hazard. A general question of how fast does the high expansion foam have to fill the space depends
upon if the hazard has a sprinkler system or not and how the building is constructed. As an example, rub-
ber tires have a maximum submergence rate of 7 minutes in a sprinklered building of light or un-protected
steel construction. The same hazard in a sprinkler building with heavy or fire resistive construction has a
maximum submergence of 8 minutes. If the same hazards are not sprinklered, the foam has to fill approxi-
mately 30 percent faster.

Figure 4

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High Expansion Foam Systems

NFPA 11 makes an allowance for the submergence time to be timed 30 seconds after the auto-
matic detection has activated the system, meaning high expansion foam must be discharging from the
generators within 30 seconds of system activation. If a delay longer than 30 seconds occurs, some sort of
system design change must occur. The most likely cause of foam not discharging from the high expansion
foam generators in 30 seconds is transit time from the deluge valve to the generator or that adequately
proportioned foam solution is not provided to the generator. In the case of transit time being too great, you
try to shorten your distance to the generators, which may mean changing the supply piping to the genera-
tors. In the case of the proportioning not being correct for the foam solution, there are a variety of cause
and effects, such as the wrong proportioning method chosen, foam concentrate not being present at the
proportioning device at the same time the water is passing through it, foam concentrate supply piping has
excess fittings, not enough straight piping on the supply or discharge of the proportioning device.

SYSTEM COMMISSIONING

A high expansion foam commissioning test is an event. The only way to prove that the system is
designed and installed correctly is to activate the system. In the past 7 years, high expansion foam has
grown in the protection of aircraft hangars. The largest single reason is that it will generally have a lower
water requirement over other protection methods. For an example, we’ll use a 50,000 sq. ft. Group 1
hangar that will not house aircraft with wing projections over 3000 sq. ft., you have (3) protection options:

1. Low expansion foam deluge systems at the ceiling

2. Low expansion foam system at the floor and over head sprinklers
3. High Expansion foam system covering the floor and overhead sprinklers

Option 1 will require a .16 gpm per sq. ft. (6.51 lpm per sq. m) of low expansion foam designed over
the entire ceiling, having a minimum demand of 8,000 gpm (30,283 lpm). Option 2 would require a .10 gpm
per sq. ft. (4.07 lpm per sq. m) of low expansion foam over the floor area and a design of .17 gpm per sq.
ft. over 15,000 sq. ft. (6.92 lpm per sq. m over 4,572 sq. m) for water sprinklers at the ceiling, requiring a
minimum water flow demand of 7,550 gpm (28,580 lpm). Option 3 would require a design of 3 cubic ft per
square ft over the hangar floor and a design of .17 gpm per sq. ft. over 15,000 sq. ft. (6.92 lpm per sq. m
over 4,572 sq. m) for water sprinklers at the ceiling, for a minimum water flow requirement of 5,550 gpm
(20,820 lpm).

When you discharge a high expansion foam system in a hangar, you will generally operate the
system for (4) minutes, the first minute is to ensure that you cover the floor and the additional (3) minutes
are generally needed to ensure you have submergence. Once you have the hangar full of soapy bubbles,
what do you do with it? One thing you don’t want to do is just open the doors, otherwise you’ll have big
clouds of soapy bubbles blowing across the airport and disrupting take-off and landings. Prior to activat-
ing the system, ensure that you have some hose lines with fog nozzles to spray down the foam to break
it down. Once you hit high expansion foam with water spray it readily breaks down and will go down the
drain.

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 High Expansion Foam Systems

CONCLUSION

High expansion foam systems have been in use for many years and are gaining popularity for a
variety of protection schemes. The equipment is specialized and the protection schemes are different than
standard sprinkler protection. Before quoting, designing, or installing a high expansion foam system, one
should consult the NFPA standard that governs the design and installation for the hazard and probably
speak with a manufacturer/provider of the equipment for further guidance. Each manufacturer has specific
high expansion foam concentrate that is tied to their high expansion foam generator’s performance, and
the manufacturer will generally lead a contractor through the steps required to install their equipment cor-
rectly.

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 High Expansion Foam Systems

High Expansion Foam Concentrate and water are Foam is an effective method for reducing and
mixed in the correct proportion by various methods controlling fire intensity and decreasing LNG vapor
to form a foam solution. This solution flows to the generation.
High Expansion Foam Generator (HEFG) with a
water powered motor. It is then discharged through METHOD OF EXTINGUISHMENT
a nozzle onto a fine mesh stainless steel screen. A
rotating fan (powered by the water motor) in the When the High Expansion Foam is discharged into
generator forces large volumes of air through the a fire compartment, three extinguishing
stainless steel screen as the foam solution is mechanisms simultaneously occur:
sprayed onto it. The air mixes with the foam
solution to form a large discharging mass of stable 1. The large mass of the discharging foam fills all
bubbles at a rate of up to 940 gallons of expanded voids and seals the area involved in the fire and
foam for each gallon of foam solution. This clean prevents fresh air from reaching the base of the
highly expanded foam mass quickly fills large areas flames. The foam mass maintains an oxygen
flowing around obstacles and flooding every void deficient area until the fire is extinguished.
smothering the fire quickly and effectively.
2. The steam generated is a result of the radiant
heat from the fire evaporating the water in the
The output of a Chemguard High Expansion Foam
foam blanket. This conversion to steam absorbs
Generator (HEFG) in a fixed installation depends on
large quantities of heat and the resulting steam-
which generator is selected. These generators are
air mixture is well below the oxygen level that is
available in a wide output range (in cubic feet per
required to support continued combustion.
minute) at various foam solution inlet pressures.
When multiple units are used an almost limitless 3. The cooling effect of the Hi-Ex foam occurs as
output can be achieved. The HEFS is suitable for the bubbles break and release water onto any
use for fire extinction of solid fuel or flammable hot surfaces. The surface tension of the draining
liquid fires in areas where the expanded foam can water is lowered and the cooling and wetting
be contained. effect of the draining water penetrates any Class
“A” type materials more rapidly than water. This
Examples:
cools the burning material to below its ignition
• Ship holds temperature.
• Aircraft hangars INSTALLATION
• Hazardous material/waste storage areas
The High Expansion Foam System (HEFS) must be
• Flammable liquid packaging areas designed and installed in strict accordance with
• Flammable liquid drum storage NFPA 11 (2002 or later) Standard for Low-,
Medium-, and High Expansion Foam and any
• Warehouse areas such as: Rolled paper, tire guidelines established by the "Authority Having
storage, in rack storage of combustible Jurisdiction" or Insurance Provider.
materials and boat storage
Chemguard recommends a contractor having
High Expansion Foam Systems have been installed previous experience in installing fixed fire protection
as added protection for Liquid Natural Gas (LNG) foam systems install the HEFS. Upon installation,
facilities where it is used as a fire suppressant and the HEFS components should be located and
for controlling vapors released from an accidental arranged so that any recharging, inspection, testing
LNG spill. Blanketing spills with High Expansion or general maintenance will cause a minimum

CHEMGUARD
204 S. 6th Ave • Mansfield, Tx 76063 • (817) 473-9964 • FAX (817) 473-0606
www.chemguard.com
DATA SHEET #D10D03180
REVISION: 05/2007
disruption to the fire protection system. The HEFG The minimum total depth of foam is to be not less
may be installed in either a vertical or a horizontal than 1.1 times the height of the highest hazard
position. being protected but in no case can it be less than 2
ft. above that hazard. Submergence time varies
When mounting a generator in a fixed location, care with the type of building construction and if the
should be taken so as not to distort the cylinder building has a sprinkler system.
section of the generator housing as this could
interfere with the rotation of the fan/motor Figure 25: provides maximum submergence times
assembly. The generator should be supported from in minutes for high expansion foam measured from
the bottom not the top and both the front and the the start of foam discharge. The chart does not
rear. It is imperative that the generator be firmly include submergence times when used on water
braced to ensure there is no flex or movement miscible/polar solvent type fuels or flammable
when the system is in operation. liquids having a boiling point less than 100ºF
(38ºC). These products may require higher
application rates. Please check with the
PIPING MATERIALS
engineering department at Chemguard for
Stainless steel 304, 316, brass, galvanized and application guidelines. When used in tire storage
black steel pipe are suitable for use with foam areas, the submergence time shown reflects the
solutions. The black steel pipe is only area also having sprinkler protection. When certain
recommended for use with foam concentrates when combustible products are stored 15 feet or higher,
the pipe is kept flooded at all times. Stainless steel fire spread may still be rapid and the discharge
pipe is suitable for use with foam concentrates at all times in the submergence chart may not be
times. Galvanized pipe cannot be used with foam suitable. A faster submergence time may be more
concentrate. appropriate.

The foam discharge rate is to be sufficient to satisfy

It is recommended that where threaded pipe joints the foam depth requirements and submergence
are in contact with the foam concentrate or the times allowing compensation for normal foam
foam solution, a quality Teflon™ based pipe joining shrinkage, foam leakage and breakdown effects of
compound and a quality Teflon™ tape in any sprinkler discharge.
accordance with MIL- T-27730 are both used to
ensure leak tight screw fittings.
The factor for compensation for normal foam
shrinkage is 1.15.
DESIGN INFORMATION
The compensation factor for loss of foam due to
For Aircraft Hangars please see the red tab leakage around doors, windows and through
“AIRCRAFT HANGARS” in this manual. unclosable openings is determined by the design
engineer after proper evaluation of the structure.
This factor cannot be less than 1.0. Depending on
TOTAL FLOODING SYSTEM is a fixed foam fire
foam expansion ratio, sprinkler operation and foam
protection system consisting of the High Expansion
depth, this factor may be as high as 1.2 for a
Foam Generators, proportioning system, foam
building with all openings normally closed.
concentrate, water supply and necessary
interconnecting piping. This type system is
The factor (Rs) for compensation of breakdown by
designed to discharge the expanded foam into an sprinkler discharge is determined by the following
enclosed space or around the hazard. The total formula or by test:
flood system is suitable for use where there is a
permanent enclosure around the hazard that is RS= S X Q where
capable of holding the required amount of foam for
the designed duration. S = Foam breakdown in cfm per gpm of sprinkler
discharge. S is to be 10 cfm/gpm (0.748
cu. M/minutes/L/minutes)
For adequate protection, there should be sufficient
foam concentrate to allow the system a discharge Q= Estimated total discharge from maximum
rate sufficient to cover the hazard to an effective number of sprinklers expected to operate
depth before any unacceptable damage occurs. gpm (L/minutes)

CHEMGUARD
204 S. 6th Ave • Mansfield, Tx 76063 • (817) 473-9964 • FAX (817) 473-0606
www.chemguard.com
DATA SHEET #D10D03180
REVISION: 05/2007
The following is the formula for calculating the EQUIPMENT LIST
minimum rate of foam discharge or total generator
capacity allowing for compensation of normal foam 1 x High Expansion Foam Generator 12,000 CFM /
shrinkage, foam leakage and breakdown effects of 59 psi /170 gpm
sprinkler discharge:
1 x 3" Between flange style, Ratio controller, Flow
range 70 – 750 gpm
Formula for Calculating
R (V/T + RS) x CN x CL where:
3 3 1 x 50 Gallon Vertical Bladder Tank
R Rate of discharge in m /min (ft / min)
3 3 (170 gpm x 0.02 - 3.4 gpm of 2% High-X Foam x 15
V Submergence volume in m (ft )
minutes = 51 gallons of foam concentrate)
T Submergence time in minutes
3 3
RS Rate of foam breakdown by sprinklers in m / min (ft /min)
CN Compensation for normal foam shrinkage
55 x Gallons High-X Foam Concentrate
CL Compensation for leakage
(51 gallons system fill, 4 gallons system test)

Plus miscellaneous swing checks and ball valves

All openings such as doorways, windows, etc.
below the design filling depth shall close
automatically before or during foam discharge when LOCAL APPLICATION SYSTEM
the system is activated.
This type of system consists of a fixed foam-
DISCHARGE DURATION: There shall be sufficient generating device complete with the necessary
high expansion foam concentrate and water to piping and foam concentrate proportioning
allow continuous operation of the system at the equipment. The system is designed to protect a
design density for 25 minutes or to generate 4 times specific piece of equipment or discharge directly
the submergence volume, whichever is less, but in onto a potential hazard area. Local application
no case less than enough for a 15 minute systems can be used to protect hazards located
discharge. indoors, outdoors or in partly sheltered areas. When
used outdoors or in partly sheltered areas,
Following is a typical High Expansion Foam System provisions should be made to compensate for the
for a building without a sprinkler system: effects of wind or other climatic conditions.

Building: Light Steel, No Sprinklers

Size: 100 ft. x 30 ft. x 10 ft.

Products Stored: Low density combustibles 7 ft. in height

Cubic area to be protected: 100 x 30 x 9, 2 ft. above height

of combustibles=27,000 cu. ft.

Fill Time: Per NFPA 11, 3 minutes

Formula for system without sprinklers

R = (V/T) x Cn x Cl

V = 27,000 cubic feet

T = 3 minutes

Cn = 1.15

Cl = 1.1 (slight leakage)

R = (9,000) x 1.15 x 1.1 = 11,385 cfm

11,385 cfm is required for the above building.

CHEMGUARD
204 S. 6th Ave • Mansfield, Tx 76063 • (817) 473-9964 • FAX (817) 473-0606
www.chemguard.com
DATA SHEET #D10D03180
REVISION: 05/2007
 FIG. 25

MAXIMUM SUBMERGENCE TIME (MINUTES) FOR HIGH EXPANSION

FOAM MEASURED FROM START OF ACTUAL FOAM DISCHARGE

Heavy or Protected
Light or Unprotected or Fire-Resistive
Steel Construction Construction
Hazard _________________________________________________
Not Not
Sprinklered Sprinklered Sprinklered Sprinklered
________________________________________________________________________________
Flammable liquids [flash points below 38ºC(100ºF)]
having a vapor pressure not exceeding 276 kPa
(40 psia) 3 2 5 3

Combustible liquids [flash points of 38ºC (100ºF)

and above]a 4 3 5 3

Low-density combustibles (i.e., foam rubber, foam

plastics, rolled tissue, or crepe paper) 4 3b 6 4b

High-density combustibles (i.e., rolled paper kraft

or coated banded) 7 5b 8 6b

High-density combustibles (i.e., rolled paper kraft

or coated unbanded 5 4b 6 5b

Rubber tires 7 5b 8 6b

Combustibles in cartons, bags, fiber drums 7 5b 8 6b

a
Polar solvents are not included in this table. Flammable liquids having boiling points less than 38ºC (100ºF) might require higher application
rates. See NFPA 30.
b
These submergence times might not be directly applicable to storage piled above 4.6m (15ft) or where fire spread through combustible
contents is very rapid.

CHEMGUARD
204 S. 6th Ave • Mansfield, Tx 76063 • (817) 473-9964 • FAX (817) 473-0606
www.chemguard.com
DATA SHEET #D10D03180
REVISION: 05/2007