Safer with FR #2 — FR in Traditional and Modular Construction

This article provides an in-depth analysis of Paged Plywood’s fire-retardant (FR) plywood portfolio, aiming to deliver a comprehensive guide for construction professionals, architects, engineers, project managers, and prefab manufacturers. It goes beyond a typical product catalog, establishing clear decision-making frameworks based on fire safety engineering principles, regulatory requirements, and practical application conditions.

The central thesis of the article is this: effective material selection for fire safety is a multidimensional process that goes beyond a single fire classification. It requires a holistic assessment of the structural element’s function, its operating environment, and specific material parameters such as structural, acoustic, and aesthetic properties. Paged Plywood offers a wide range of plywood solutions that combine these complex requirements while simplifying design, approval, and construction processes. The analysis demonstrates that a structured approach to product selection minimizes design risks, ensures compliance with regulations, and enhances overall efficiency, particularly important in the rapidly developing prefabricated construction sector.

We will discuss, among others:

• Walls/ceilings: Softwood ThinPly FR, Softwood ThickPly FR, BirchPly FR
• Floors: BirchPly FRfl, Master Form FR, Mesh FR, Twin Form FR, BeechPly FR
• Special solutions: BeechPly Phon FR, DryGuard FR

The Changing Landscape of Fire Safety in Construction

Modern construction—both in the public and private sectors, and especially in prefabricated technology—places increasing emphasis on fire safety and operational continuity. Growing expectations for user safety and property protection require the use of materials that behave predictably when exposed to fire. In this context, fire-retardant plywood represents a key solution, combining the natural advantages of wood—such as lightness, rigidity, ease of processing, and aesthetics—with controlled fire performance.

The use of pre-classified FR plywood translates into a range of tangible benefits for professionals:

• Simplified regulatory compliance: Using materials with clearly defined fire reaction classes, such as B-s1,d0 (for walls and ceilings) or Bfl-s1 (for floors), makes it easier to meet design and legal requirements.
• Enhanced user safety: The use of FR plywood significantly improves safety in case of fire, as the material emits little smoke (s1 classification) and does not produce flaming droplets (d0 classification). Smoke is the leading cause of death in building fires, and the absence of flaming droplets prevents the spread of fire and eliminates additional hazards for evacuating occupants.
• Streamlined approval process: Since the required fire class is achieved at the material level, often without the need for additional coatings, the fire approval path becomes shorter and more predictable.
• Standardization in prefabrication: In modular construction, where buildings are assembled from 2D or 3D elements, the use of FR plywood ensures repeatability and consistency in fire classifications. This facilitates serial design and acceptance processes that require compliance with uniform safety standards.

Understanding Euroclass Fire Reaction Classifications: A Technical Overview

The fire reaction classification of construction products in Europe is based on the harmonized EN 13501-1 standard, which assesses a material’s contribution to fire development. Understanding the individual designations is crucial for designers and contractors.

• For walls and ceilings: B-s1,d0
  • B: Indicates that the material is flame-retardant and contributes only to a limited extent to fire growth. This is a fundamental and mandatory criterion for vertical and horizontal surfaces.
  • s1: Indicates very low smoke emission. This parameter is critical for user safety. Low smoke levels help maintain visibility on evacuation routes, providing more time for safe escape and assisting firefighters during rescue operations. Reduced smoke emission directly translates into a lower risk of suffocation.
  • d0: Indicates no flaming droplets or particles during combustion. This is important because flaming droplets falling from burning surfaces can ignite other materials at a distance, contributing to rapid fire spread and posing a direct threat to people in the fire zone.
• For floors: Bfl-s1
  • Bfl: This designation is specific to flooring (fl = floor). It means the material is flame-retardant, and its fire performance has been tested under conditions appropriate for horizontal surfaces. Fire spread characteristics differ between horizontal and vertical surfaces, hence the need for separate classification.
  • s1: Indicates very low smoke emission, which is as important for floors as for walls and ceilings. In evacuation routes, this parameter is crucial: low smoke levels in rooms and corridors are essential for safe evacuation.

These classifications form the legal and technical framework that directly impacts the design of safe buildings. By selecting material with the appropriate class, the designer not only fulfills formal requirements but also significantly increases the operational safety of the building.

Structured Framework for FR Plywood Selection: The Extended 5-Step Model

The selection of FR plywood should be based on a five-step decision-making process that enables conscious and precise product choice.

Step 1: Define the application and required fire class
The first and most important question is to precisely determine in which part of the building the plywood will be used. The answer is binary and determines the required fire class. For walls and ceilings, a board with class B-s1,d0 must be used, while for floors, class Bfl-s1 is required. This initial step is crucial, as it immediately filters the entire product portfolio.

Step 2: Assess operating and environmental conditions
Once the basic fire class has been established, the conditions under which the surface will be used must be taken into account.

• Traffic intensity and loads: In high-traffic areas such as corridors, entrances, or platforms, a board with high load-bearing capacity and rigidity is required. The choice of wood species (e.g., beech vs. birch vs. softwood) is dictated by strength requirements.
• Moisture risk during assembly: In prefabricated construction, where assembly often takes place in open conditions, there is a risk of material exposure to moisture. In such cases, a board with a protective layer for the construction phase should be considered, such as Paged DryGuard FR, whose hydrophobic coating protects the element from moisture and dirt before the building is “closed.”
• Acoustics: In spaces requiring noise and vibration reduction, such as auditoriums, conference rooms, or technical corridors, boards with a special damping layer should be considered, for example Paged BeechPly Phon FR.

Step 3: Identify additional functional requirements
The next stage is to match additional parameters that may be critical for a given project.

• Anti-slip properties: Where user safety is a priority, such as at entrances, ramps, or platforms, anti-slip surfaces with embossed textures are necessary, e.g., Paged Mesh FR.
• Low weight: In 2D/3D modular or temporary constructions where ease of transport and installation is important, lighter compositions such as Paged Softwood ThinPly FR or Paged Twin Form FR are preferred.
• Combination of functions: Some boards, e.g., Paged BeechPly Phon FR, combine fire performance with acoustic properties, reducing noise and vibrations. This is an example of a material that solves two problems simultaneously, which is particularly valuable in complex projects.

Step 4: Define the required finish
FR plywood offers different surface finishes adapted to final use.

• Smooth phenolic film: Provides an even base for coverings or elastic floors, reducing finishing work.
• Anti-slip film (mesh): A functional and safe finish, ideal for walkways and stairs.
• Raw surface: Intended for further processing, such as lacquering or veneering, allowing for an aesthetic appearance essential in representative spaces such as lobbies or reception areas.

A practical rule is always to evaluate the application of the chosen lacquer, adhesive, or paint on a sample from the same batch to ensure the result meets expectations.

Step 5: Verification and compliance documentation
The last but equally important stage is confirming that the selected product meets all project requirements. The professional is responsible for reviewing technical documentation, including the Declaration of Performance (DoP), test reports, and compliance with standards and investor specifications. This is a continuous process that minimizes the risk of errors and ensures successful project acceptance.

Comprehensive Product Portfolio Analysis

Walls and Ceilings (class B-s1,d0)

• Paged Softwood ThinPly FR: A lightweight coniferous plywood panel whose use as cladding allows for lighter partitions while maintaining stiffness. Its stability and ease of CNC machining make it ideal for producing 2D panels in prefabrication.
• Paged Softwood ThickPly FR: A thick coniferous plywood panel that provides high stiffness, making it suitable for applications where cladding also serves as structural reinforcement, such as in wall panels or 3D modules resistant to stress during transport.
• Paged BirchPly FR: A hardwood plywood panel with high dimensional stability and aesthetic qualities, making it suitable for representative spaces such as receptions or lobbies. An important technical aspect to verify is that the fire classification depends on thickness. For thicknesses of 6.5 mm and 9 mm, BirchPly FR is not a structural plywood, and its fire classification is B-s2,d0. For the remaining thicknesses in the range of 12 to 30 mm, the fire classification is B-s1, d0. Designers must carefully review documentation to ensure the chosen thickness meets required standards.

Floors (class Bfl-s1)

• Paged BirchPly FRfl: A flooring-grade hardwood plywood variant, intended for areas with intensive traffic and heavy loads, such as school corridors or communal zones in residential buildings. The Bfl-s1 class is available in thicknesses from 9 to 45 mm, offering wide application flexibility.
• Paged Master Form FR: A panel with a smooth phenolic film that provides an even, stable base for coverings and elastic flooring. It is the optimal choice where fast installation and durability are key.
• Paged Mesh FR: Equipped with an anti-slip phenolic mesh, this panel is dedicated to areas where safety is a priority, including entrances, ramps, platforms, and corridors. The Bfl-s1 classification for this product is available for 35–45 mm thicknesses, which must be verified in the technical datasheet.
• Paged Twin Form FR: A hybrid panel combining hardwood and softwood layers. It offers a favorable strength-to-weight ratio, making it ideal for temporary walkways on construction sites or modular 2D/3D structures where ease of transport and installation is crucial.
• Paged BeechPly FR: A beech plywood panel designed for applications requiring remarkably high loads, such as stairs, mezzanines, or technical zones. Its exceptional strength makes it the optimal choice for the most demanding structural elements.

Special Applications

• Paged DryGuard FR: This product was designed to address the challenges of open-state construction. Its hydrophobic coating protects structural elements from moisture and dirt during the construction phase before the building is “closed.” The panel combines installation protection with the required B-s1,d0 fire classification.
• Paged BeechPly Phon FR: This composite is an innovative solution that combines fire-retardant properties with effective noise and vibration damping thanks to a special acoustic insert. It is ideally suited for conference rooms, technical spaces, or corridors where sound transmission must be reduced while maintaining fire safety requirements.

Decision Support Matrix: A Practical Reference Tool

The following table presents a consolidated matrix that facilitates the selection of the appropriate Paged FR plywood, combining example applications with key technical and functional parameters.

*Notes: Thickness limitation for Bfl-s1: according to technical sheets, BirchPly FRfl and Master Form FR — Bfl-s1 applies to 35–45 mm. For Mesh FR, confirm in current datasheet (typically 35–45 mm). Twin Form FR: Bfl-s1 across a wide range (9–40 mm).

Compliance and Sustainability: Navigating the Future of Construction

Compliance with regulatory standards and sustainable building criteria is becoming an increasingly important aspect of the design process. Paged FR plywood is manufactured from certified wood sources, which represents the first step toward sustainable production. These products carry mandatory CE marking and a Declaration of Performance (DoP), confirming their compliance with EN 13986 under the Construction Products Regulation (CPR). Formaldehyde emissions meet the strict E1 class, and in many cases are even lower, which reflects the manufacturer’s voluntary commitment to ensuring above-standard health-friendly product properties.

The growing emphasis on transparency and environmental responsibility is reflected in the availability of Type III Environmental Product Declarations (EPDs) for key products. EPDs provide verifiable data on the environmental impact of a product throughout its life cycle, which is essential for projects pursuing sustainable building certifications such as BREEAM or LEED.

Upcoming regulatory changes, including the new Construction Products Regulation (CPR, EU) 2024/3110 and the introduction of the Digital Product Passport (DPP), herald a fundamental shift in documentation. The DPP will be the primary mechanism for digital identification, tracking, and verification of product compliance throughout its entire life cycle. The fact that manufacturers like Paged are already preparing for these changes demonstrates their proactive approach, which from the perspective of designers and investors translates into simplified verification processes and easier completion of documentation in the future.

Conclusions: A Structured Approach for Optimal Outcomes

The effective selection of fire-retardant plywood is a strategic process that requires the integration of many variables: from the key fire reaction class, through the functional and aesthetic requirements of the project, to aspects of sustainability and regulatory compliance. A simple approach—based solely on choosing a material with the appropriate fire class—is insufficient.

The five-step decision-making model presented in this article provides a systematic and reliable tool that guides professionals through all stages of selection—from defining the element and its function, through assessing operating conditions, verifying documentation. In this way, it ensures that the decision is not only quick and informed, but above all safe and compliant with legal requirements.

Paged’s FR product portfolio offers a complete range of solutions for every scenario discussed, from lightweight softwood cladding panels, through durable flooring, to specialized acoustic and hydrophobic variants. Using this structured approach enables optimal design decisions that translate into more efficient, safer, and regulation-compliant buildings—aligned with the latest trends, including the rapidly growing 2D/3D prefabrication technology sector.