Fire Wall

ew regulations often create opportunities for manufacturers to develop new or improved
products for specific markets. Such is the case with the State of California’s new Technical
Bulletin (Cal. TB) 603, which mandates that, effective Jan. 1, 2005, mattresses, box springs and
futons sold in that state to consumers must be open-flame-resistant. The regulation, which also
serves as a model for a proposed national standard, has spurred a number of fiber and fabric
producers to introduce compliant products that will enable end-product manufacturers to stay

Among the players in this market is Johnston Textiles Inc., Phenix City, Ala., whose Phenix
Barrier® woven and nonwoven fabrics contain a proprietary blend of readily available raw materials
that provide protection from open-flame sources. The company — a niche manufacturer formed earlier
this year when a management team from Johnston Industries Inc. acquired that company’s fabric and
testing businesses — says the products can be produced on conventional textile equipment and offer
an affordable solution to meet or exceed Cal. TB 603 requirements.

“Our products are highly specialized,
and performance is their most important aspect,” said L. Gene Cone, president and CEO. “Johnston
Textiles is in the business of developing technical textile solutions that meet our customers’
customers’ needs.


The photographs above, taken three minutes into a burn test, compare the flame resistance
of a mattress made with Phenix Barrier® (top) with that of a standard mattress (bottom).

“Mattresses are a case in which
legislation has finally caught up with the need. For example, Johnston already supplies
flame-resistant products to institutional markets, such as the US Navy,” Cone continued. “We now
have some very unique products that offer a good balance between performance and cost.”

Phenix Barrier W is a soft, drapable woven cotton/coated fabric for use on high-fuel-load
mattresses such as those made with a high proportion of urethane. Phenix Barrier NW is a needled
nonwoven fabric made from blended fibers. Used on the top panel of the mattress, it provides added
cushioning as well as flame resistance. The two products can be combined in a mattress — with the
nonwoven fabric on the top and bottom panels and the woven on the borders, where the coil springs
place more tension on the fabric, which over time would cause fiber-to-fiber slippage in the
nonwoven barrier. The woven fabric also is used on pillow-top mattresses where the pillow top joins
the mattress and off-gassing could occur from the mattress filling.

The barrier fabric is placed between the filling and the ticking. In open-flame testing, the
ticking burns, but the barrier resists the flame and maintains its strength, insulating the filling
from the flame and the oxygen it requires to burn. Johnston also will be conducting accelerated
aging tests to simulate effectiveness over time.

“We’ve come up with a simple solution — using a nonwoven barrier on the panels and a woven
barrier on the sides — that should still be effective 10 years later,” said Marty Odum, vice
president, market development. “Even the nonwoven product should maintain its strength.”

The company says numerous bedding manufacturers have expressed interest in using Phenix
Barrier in their mattresses.

For more information about Phenix Barrier®, contact Bill Maher (770) 502-9752;

May 2004