Modeling Gypsum Board to Complement Full-Scale Fire-Resistance Testing

Key Points

• UL Solutions offers a service using validated thermal modeling and simulation to evaluate gypsum board designs.
• Manufacturers can evaluate designs before full-scale fire-resistance testing.
• Modeling complements but does not replace physical testing.

UL Solutions' new modeling and simulation service is designed to give gypsum board manufacturers earlier insight into thermal performance, allowing them to compare designs, focus development resources and prepare for full-scale fire-resistance testing.

What has UL Solutions launched?

UL Solutions has introduced a digital engineering service that uses validated thermal modeling and simulation to evaluate gypsum board designs during product development.

The service is intended to help manufacturers understand how design decisions may affect thermal performance before full-scale fire-resistance testing.

Why is UL Solutions offering this service?

Gypsum board development has traditionally relied heavily on physical testing. As manufacturers work to shorten development cycles, manage costs and consider more design alternatives, modeling and simulation can provide useful information earlier in the process.

The service can help manufacturers screen formulations, identify promising options and make more focused development decisions.

How does the modeling and simulation service work?

The service uses thermal modeling methodologies based on UL 263, the Standard for Fire Tests of Building Construction and Materials, and ASTM E119 fire-test approaches.

The modeling framework incorporates UL 263 furnace conditions, realistic boundary conditions, material property characterization and gypsum dehydration behavior. These elements can help manufacturers assess how design choices could influence thermal performance under modeled conditions.

What types of products and assemblies could the service support?

The service focuses on gypsum board, a component used in fire-resistance-rated wall, floor and ceiling assemblies in commercial and residential construction.

What business and development needs can modeling address?

The service is designed to support the following:

• New product development and formulation screening
• Product optimization
• Material substitution assessments
• Cost-reduction initiatives
• Recertification support
• Research and development evaluation before full-scale testing

Potential benefits include reduced development risk, fewer unproductive test iterations and more focused use of laboratory resources.

Does modeling replace physical fire-resistance testing?

No. Modeling and simulation do not replace physical testing required for certification or applicable code and regulatory requirements.

Instead, simulation complements UL Solutions' existing testing, inspection and certification services.

Modeling can inform early development decisions that a customer may choose to make, while physical testing and certification provide the evidence and independent evaluation needed to assess products against applicable requirements.

How could the service affect a manufacturer's gypsum board product development?

Manufacturers can use modeled results to compare design alternatives and identify promising options prior to full-scale testing.

This approach could support more agile design and earlier development decisions.

What does the launch mean for fire safety?

During product development, earlier insight can help manufacturers better understand how design choices may influence thermal performance under modeled conditions. That insight could support the development of more robust fire-resistant products while maintaining the rigor of physical testing and certification.

The service also illustrates how digital engineering can work alongside established fire science rather than replacing it.

Where can I learn more?

Additional information about the new service is available in the Oct. 6 press release.

More details about UL Solutions' services are available on the modeling and simulation pageat UL.com.