The Challenge
Belcanto developed the Grappler Balcony, an innovative, lightweight aluminium balcony structure created to address common issues with traditional on-site balcony construction. The Grappler’s off-site, pre-assembled design allows it to be easily installed, reducing on-site construction time. However, the use of aluminium presented unique challenges due to its known performance in fires, as aluminium has a tendency to melt at high temperatures, complicating its compliance with New Zealand’s fire safety standards.
When multiple fire engineers and consent authorities reviewed the balcony’s design, they reached different conclusions on how best to show it met the fire safety requirements, especially concerning structural stability during fires. To standardise compliance across projects and streamline the consent process with Auckland Council and Fire and Emergency New Zealand (FENZ), Belcanto approached Origin Fire for a solution.
The Solution
Origin Fire’s Joanna Williams led the project, applying a first-principles approach to determine compliance with the building code. This approach involved assessing the type of fire exposure the balcony might experience and designing a fire test that could replicate such conditions. Key steps in this approach included:
- Pathway to Compliance: Origin Fire documented a clear “Pathway to Compliance” report, detailing how the balcony could meet building code requirements. This report was shared with Auckland Council’s chief fire engineer and FENZ engineers, securing consensus on the methodology before testing began.
- Testing Approach: Two scenarios were prepared: one for balconies attached to sprinkler-protected buildings and one for those without sprinkler systems. Testing parameters were set to evaluate the Grappler Balcony’s performance under each condition, focusing on temperatures that could affect aluminium stability.
- Structural Assessment with Temperature Impact: Working alongside a structural engineer specialising in aluminium, Joanna analysed the impact of raised temperatures on the balcony’s structural members. She calculated the temperatures at which the aluminium components could lose stability, ensuring the balcony would maintain structural integrity for the necessary duration during a fire.
The Outcome
The testing and documented analysis demonstrated that the Grappler Balcony met New Zealand fire safety requirements, allowing it to be approved for multiple buildings without additional delays in the consent process.
The project has since received industry recognition, earning the Innovative Product Award at FireNZ 2024, reflecting the success of Origin Fire’s approach in enabling innovative construction solutions that also meet fire safety standards.
Quote from Joanna Williams, Project Lead:
“Our first-principles approach and collaboration with structural specialists allowed us to document a compliance pathway for the Grappler Balcony that meets safety standards while supporting Belcanto’s innovative design.”
Key Fire Safety Features:
- Comprehensive compliance pathway for fire safety
- Fire test scenarios tailored for sprinkler-protected and non-sprinkler buildings
- Structural assessment for aluminium stability under elevated temperatures
Services Provided:
- Compliance documentation and fire safety pathway
- Fire test design and execution
- Structural temperature impact analysis in collaboration with experts
