Polystyrene composite panels have been the standard construction material in the food industry for a number of years. The material being light in weight, having an excellent thermal coefficient whilst being of low cost, is now the standard building material.

Unfortunately the material also has a very high fire loading.

The material when burnt gives of toxic fumes from the polystyrene and in many cases from the adhesives used to bond the material to the laminating panels. In recent years both insurers and fire authorities have expressed concern over the material, particularly after certain tragic cases that has resulted in loss of life.

In conjunction with our insurance company, the Greencore Group Board has agreed to cease using Polystyrene composite panels manufactured from combustible material for all but the most minor jobs (Note minor being defined as no more than two 2 panels without prior consultation with company insurers). This policy has been produced to provide guidance to Group companies on future use.

The Board has agreed the following criteria:

1. prior consultation with insurers is required if a development requires capital expenditure, failure to consult at an early stage will result in unnecessary delays.
2. prior consultation with insurers is required if a development will include hot spots
   e.g. ovens, fryers, cookers or naked lights i.e. char grillers, etc.
   or where the project will significantly impact on the insurance policy.
3. all electrical systems will be designed, installed and maintained
   in accordance with the Greencore Group planned preventative maintenance programme and they shall be independently audited to IEE criteria before commissioning.
4. all future Greenfield projects will be manufactured from non combustible core materials.
   (See below for approved materials)
5. all major refurbishment's will be of non combustible core materials
6. all construction work in or around hot spots e.g.. ovens, fat fryers etc.
   will be manufactured from non-combustible core materials
   and a risk assessment will be completed
   before the decision to increase the level of protection
   to that of a flame proof compound
7. All new corridors, tunnels and fire havens
   must be manufactured from non-combustible core materials.

The Board of Directors and the insurance company accepts that minor repairs can continue to be completed in Polyurethane. However, Group companies should consider the potential of single non-combustible core panels as fire breaks.

Where combustible panels are used it must be considered as the exception rather than the norm and must not exceed 2 Polyurethane panels ( Aprox. 20 m2 ) without prior consultation with insurers.

The Board has agreed to liase with the insurers on all construction projects over 20 m2 and to grant access rights for inspection purposes. All such enquiries should be channelled through the Health and Safety section based at Runcorn.

The Board accepts that in certain circumstances overcladding with non-combustible core material, in Hot Spot areas is an acceptable practice. This is to be considered as a short term practice after consultation with insurers.

Fire retardant cement (such as Monokote) can be used as an effective fire break between Polystyrene and polyurethane panels after consultation with insurers.

Contact details for company insurance brokers are available from Corporate Office at Runcorn.

Cold stores.

The reader should note that cold stores continue to present us with their own unique set of problems. These include suitable and approved construction materials and specific design issues. Greencore Group should contact Corporate office at Runcorn for specific advice and guidance.

Construction materials approved by The Greencore Group

These construction materials are only approved for use,
on new build and refurbishment programmes,
provided that they are fitted by a Company approved by the Greencore Group
and that the installer strictly adheres to the panel Manufacturers Installation requirements.

All structures will be independently audited prior to commissioning.

This is to ensure that all construction Panels have been correctly installed,
ensuring compliance with Loss Prevention Council rules
and that the materials are installed in a similar fashion
as to when they were tested and approved for use in the U.K. by the LPC.

1) PAROC

Mr Robert Gray
Paroc UK, St Helens, Merseyside

Tel No 0151 426 6555,
Fax No 0151 426 6622

PAROC
Installation requirements

2) FOAMGLASS

Flameguard Insulations Ltd.
Macadam Way
West Portway Industrial Estate
Andover
Hampshire SP10 3LF

Tel: 01734 500655

or

Foamglass Cellular Insulation
Pittsburgh Corning (UK) Ltd.
Southcourt
29 South Street
Reading
Berkshire RG1 4QU

3) FACED CEMENT BLOCK
As per your local building supplier or contractor.

4) MONOKOTE

UK Supplier;

Exton UK Ltd, 26 Solent Ind Estate,
Shamblehurst Lane, Hedgend, Southampton, SO30 2FY.

Tel 01489 788909, Fax 01489 788828

NOTE: MAN MADE MINERAL FIBRES (MMMF)

The use of man made mineral fibres e.g.; Mineral Wool, Fibre-Glass etc.
are not approved for food production areas,
as they are thought to promote bacterial growth when damp or wet
and if damaged may emit airborne fibres to the workplace.

Panels manufactured from man made mineral fibres
(including Mineral Wool, Fibre-Glass etc)
can rupture at sub zero temperatures when wet
and should therefore not be used in cold stores.

Revised: December 01, 2004.
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