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Key Takeaways
100mm AAC Panels Are the Market Standard:
The 100mm thick AAC panel is the industry benchmark in Malaysia and Singapore. It is chosen for its ability to reliably achieve a 4-hour fire rating, which meets the highest compartmentation requirements in both countries’ building codes.
100mm Delivers Robust Compliance and Easy Certification:
Using 100mm AAC panels simplifies approval with fire authorities (Bomba/SCDF) and streamlines the Certificate of Conformity (COC) process. The 100mm panel’s fire test report is recognized as the “worst-case scenario,” allowing even thicker panels (150mm/200mm) to be approved without additional destructive testing.
Integration with Standard Door Frames and Fit-Outs:
Most standard metal and timber door frames are designed for 100mm wall thickness, ensuring smooth architectural integration. Thinner panels (like 75mm) often cause fitting problems, require custom solutions, and complicate installation.
Higher Density and Proper Sealing Are Critical:
Panel density affects fire resistance—lower density may void certification. Also, joints and service penetrations must use certified fire-stop systems to maintain the 4-hour rating, as the wall is only as strong as its weakest point.
Introduction
In the global construction market, Autoclaved Aerated Concrete (AAC) panels are prized for their high fire resistance-to-thickness ratio. While international discussions often debate the efficiency of 75mm vs. 100mm panels, the construction landscape in Malaysia and Singapore has largely converged on the 100mm panel as the default specification. This preference is driven not only by the need to achieve a 4-hour fire rating but also by door frames thickness considerations, streamlined compliance certification (COC/Bomba/SCDF), and wall robustness (BS 5234) requirements.
What is the Difference Between Integrity (E) and Insulation (I) in Fire Testing?
To understand the baseline requirements, one must distinguish between the two primary failure criteria in fire testing (e.g., BS 476 Part 22), which are standard in this region: Integrity (E), the ability to prevent flames or hot gases, and Insulation (I), the ability to restrict temperature rise on the unexposed side (capped at 140°C).
| Criterion | Technical Definition | Analogy | Failure Indicator |
| Integrity (E) | The ability of the panel to prevent the passage of flames or hot gases. | “The Physical Barrier” (Dam Leaking Water) | Cotton Pad Test ignites, or 6mm/25mm gap gauges pass through. |
| Insulation (I) | The ability of the panel to restrict temperature rise on the unexposed side. | “The Thermal Shield” (Hot Pot Handle) | Avg. temperature rise exceeds $140^{\circ}C$ or hotspot rise > $180^{\circ}C$. |
The 75mm Limitation
While a 75mm panel can achieve a 2-hour rating, it sits on the “heat soak” threshold. It maintains Integrity well but often fails Insulation criteria past 120 minutes as the thin profile becomes heat-saturated.
The 100mm Benchmark
The 100mm AAC panel provides the necessary thermal lag to ensure 4-hour (240/240/240) resistance. This makes it the “Gold Standard” for compliance.
Why is 100mm the Default AAC Specification in Malaysia & Singapore?
The industry preference for 100mm is driven by three practical pillars: stringent compartmentation codes, integration with standard door frames, and streamlined Certificate of Conformity (COC) paperwork that aligns with primary test reports.
A. Fire Rating & Compartmentation
Building codes in Malaysia (UBBL) and Singapore (Fire Code) are stringent regarding compartmentation. By standardizing on 100mm, the project automatically meets the highest common requirement (4 hours). This eliminates the risk of accidentally installing a 2-hour panel in a location requiring a 4-hour rating (e.g., a party wall that aligns with a structural fire break).
B. Integration with Door Frames
A major driver for the 100mm selection is architectural fit-out logistics:
- Standard Sizing: The vast majority of standard metal and timber door frames manufactured in Malaysia and Singapore are designed to suit a 100mm finished wall thickness.
- The 75mm Problem: Using a 75mm panel often requires custom-ordered frames or additional “packing” to fit standard frames. This adds cost and complexity that outweighs the material savings of the thinner panel.
C. Certification (COC, Robustness & Acoustics)
Compliance paperwork in this region is rigorous:
- The “Base Test” for COC: Manufacturers typically conduct their primary rigorous testing—Severe Duty Robustness, STC (Sound Transmission Class), and full Fire Type Tests—on 100mm samples.
- Streamlined Submission: Using the 100mm panel ensures the product installed on-site matches the primary test reports perfectly. Using 75mm might require additional (and expensive) ad-hoc testing to prove it meets acoustic or impact requirements.
Do 150mm and 200mm AAC Panels Require Separate Fire Tests?
Thicker panels like 150mm and 200mm carry a 4-hour fire rating and are approved based on 100mm test data under the engineering principle of “Superior Performance by Design,” as greater thermal mass inherently resists heat transfer longer.
Why Thicker Panels are Accepted without New Tests
This acceptance is based on Thermal Physics: If a 100mm panel provides enough thermal mass to delay heat transfer for 4 hours, a 150mm or 200mm panel (made of the same density and chemical composition) possesses greater thermal mass and a longer thermal path. Therefore, it will inherently resist heat transfer for at least as long, if not longer, than the 100mm panel.
The “Worst-Case Scenario” Submission Logic
When a Qualified Person (QP), Fire Engineer, or Architect submits documents to authorities (such as Bomba or SCDF), they use the 100mm Fire Test Report to support the use of 150mm or 200mm walls:
- The Base Test: The 100mm report is presented as the “Worst-Case Scenario” (the thinnest allowable configuration).
- The Assessment: Since the material properties are identical, and the thickness is increased, the failure mode (Insulation rise) will be delayed further.
- Conclusion: If the “weakest” version (100mm) passes the 4-hour test, the “stronger” versions (150mm/200mm) are deemed to comply by default/assessment without needing a separate destructive fire test.
Conclusion
Standardizing on 100mm AAC panels is the most practical, safe, and cost-effective choice for the Malaysia and Singapore markets. It guarantees a 4-hour fire rating, ensures seamless integration with standard door frames, and simplifies the rigorous COC/Bomba/SCDF approval process. By using the 100mm benchmark as the “Worst-Case Scenario,” developers can confidently scale up to 150mm or 200mm thicknesses, knowing they are backed by proven engineering principles and local regulatory acceptance.
Frequently Asked Questions (FAQ)
Is AAC fire resistance better than traditional red brick?
Yes, AAC typically offers superior fire resistance due to its cellular structure, which provides lower thermal conductivity. While a standard red brick wall requires significant thickness to reach high ratings, a 100mm AAC panel inherently achieves a 4-hour rating with significantly less weight and faster installation.
What exactly is a Certificate of Conformity (COC)?
A COC is a mandatory document issued by an accredited certification body (like SIRIM in Malaysia or TUV/SETSCO in Singapore) proving the product matches the tested fire-rated specimen. Without a valid COC linked to the 100mm test report, the fire authority (Bomba or SCDF) will not grant clearance for the building’s occupation.
Does the density of the AAC panel affect its fire rating?
Absolutely; higher density generally improves the “Insulation (I)” criteria by slowing down the heat transfer through the material. Most 100mm standards are based on a specific density range (e.g., $600-700 kg/m^{3}$), and dropping below this density could compromise the 4-hour certification.
How does the fire sealant used in joints affect the overall 100mm wall rating?
A fire-rated wall is only as strong as its weakest point, which is usually the joint. To maintain a 4-hour rating, you must use an approved fire-rated sealant or thin-bed adhesive that has been tested in conjunction with the AAC panels to prevent “Integrity (E)” failure through cracks.
If I use a 75mm panel but add plaster on both sides, does it qualify for a 4-hour rating?
While plastering increases thermal mass, authorities usually require a test report for the entire system. Unless you have a specific lab report for “75mm AAC + Plaster” achieving 240 minutes, you cannot claim a 4-hour rating; this is why starting with a bare 100mm panel is the safer regulatory path.
How does the inclusion of service penetrations (cables/pipes) impact the 100mm fire certification?
Any hole cut into a 100mm AAC wall for services technically voids the fire rating unless those penetrations are sealed with tested fire-stop systems (collars, wraps, or pillows). These systems must match or exceed the 4-hour rating of the 100mm panel to maintain compartmentation.
What happens if the panel density in the test report differs slightly from the stock delivered to the site?
Authorities allow a small tolerance, but significant deviations can lead to a rejection during site audits. If the delivered panels are lighter (less dense) than the tested sample, they may fail the “Insulation” requirement, potentially requiring expensive remedial measures or re-testing.