At Innovaré, quality isn’t just a requirement—it’s the foundation of everything we build. That’s why we’ve integraIn Autumn 2024, our Technical Manager, Sam, travelled to the UAE to oversee a crucial stage of fire resistance testing for the Innovaré third-generation i-FAST panel system at the world’s only 5m fully loaded test facility.
This testing took place at the UKAS accredited Thomas Bell-Wright International Fire Test Laboratory in Dubai because the UK lacks the facilities to test panels over three meters in height. As it is not possible to extrapolate test results for height, Innovaré faced considerable challenges in proving compliance due to the restrictions of test rig heights in the UK and Europe so the process of travelling and completing the fire testing in the UAE was essential. The exacting and proven information puts us ahead of the field and is industry-leading in providing clients with the complete balance of low carbon and highly tested, fire-compliant solutions.
The goal of this visit was ambitious: to validate a 120-minute fire resistance wall system. The outcome surpassed expectations. The wall achieved an REI 120 classification, far exceeding the standard 60-minute benchmark. Thanks to the system’s advanced insulation, even the outer boards remained intact. These results provide robust, validated assurance that our timber panelised systems do not just comply with regulations—they outperform them.
But achieving this milestone was not simply about the test itself. It was the result of months of planning, preparation, and firsthand execution. This investment was underpinned by our value proposition of designing Low Carbon Fire Safe products and delivering Low Risk Rapid Build offsite construction solutions. Here is a look at the journey from start to finish.
From Planning to Dubai
The process began with planning: identifying what needed to be tested by analysing market demands and customer needs against gaps in our current offer. From there, the design team produced detailed drawings of the i-FAST panels, ensuring every specification aligned with the rigorous standards of fire testing.
Next came quantifying. A detailed materials list was prepared, double-checked against drawings, and expanded to account for wastage. Once materials were sourced, they were packed into a custom-built crate before being shipped by sea freight to Dubai. With over a 10,000 nautical mile journey around the continent of Africa – there was no room for error.
While the materials were in transit, Sam prepared for his own journey. With a seven-hour flight and a three-hour time difference, he coordinated with the lab to ensure everything would be ready upon arrival.
Building & Preparing the Test Specimen
Once in Dubai, the real work began. On unpacking, the team faced challenges: Not least the extremely hot and humid conditions under which they were working.
The panel was then built directly into the rig to meet the tight tolerances of the furnace aperture. Careful offsetting of board edges and precise jointing ensured the test specimen was fully compliant with the requirements of the test standard. Every screw head was filled, edges were blended, and joints were reinforced with paper tape and plaster attention to detail that Critical to ensure compliance with the BS EN 1365-1 standard and as built details.
Into the Furnace
With the specimen complete, it was lifted onto the furnace by the lab technicians. At ignition, temperatures quickly climbed past 600°C, while hydraulic rams apply over 40kN of pressure sensors logged every shift in temperature and deflection.
This stage demanded patience. Once the test begins, there is nothing to do but monitor the readings—a tense waiting game where minutes feel far longer than they are.
Redefining Standards in Fire Safety
The Dubai test marked more than just a technical achievement. It provided precise, data-backed evidence that Innovarés i-FAST system is a reliable and compliant product for modern methods of construction.
For clients and stakeholders, this means greater confidence in compliance and performance. For Innovaré, it is another step in our mission to deliver #LowCarbonFireSafe building products and #LowRiskRapidBuild solutions.
Dubai was not the end of the journey, but part of an ongoing cycle of testing, validation, and improvement. By investing in these processes, we ensure our systems not only meet today’s demands but are prepared for the challenges of tomorrow.
