LED Downlights + PFP.

Ceiling cross-section showing LED wafer light with fire protection cones and text overlay about LED light safety.

Discover the importance of properly fire rating compromised openings, created by LED wafer-styled downlights – and how to effectively resolve this life safety issue.

When it comes to designing a space – whether it’s a luxury hotel lobby or a restaurant renovation – lighting is often one of the essential components in the overall building’s design. It sets the mood, enhances the functionality, highlights the building’s aesthetics, and even impacts energy efficiency.

However, selecting the correct lighting is more than just brightening the room. For example, would you specify a low-lumen light in an operating room? A high-lumen light for a newly renovated fine dining restaurant? No, of course not.

In addition to a fixture’s lumen output, construction professionals need to consider ceiling height, safety requirements, and the building’s aesthetics when selecting their lighting of choice. Therefore, selecting the right lighting fixture isn’t a design decision – it’s a strategic one.

One fixture that’s been checking all the right boxes lately? Low-profile LED downlights.

LED Downlights. Pancake lights. LED Wafer-Styled lights. LED Wafers. Whatever you want to call them. Low-profile LED Downlights have become a popular lighting trend in modern-day construction. But what makes these slim fixtures so popular on job sites across the United States? Let’s break it down.

LED Wafers in Today’s Construction Methods

In today’s construction world, efficiency, flexibility, and aesthetics are key – and that’s exactly why low-profile LED downlights have become a favorite among architects and contractors.

Formulated with an ultra-thin design, LED downlights can fit into tight ceiling spaces where traditional recessed lighting simply won’t work. Whether it’s a hotel relighting renovation or a new construction multi-family complex, their compact design makes them incredibly versatile.

Beyond their size, low-profile LEDs are also known for their installation process. With integrated junction boxes and no need for bulky housings, they’re quick to install – allowing for a reduction in labor time.

Plus, they’re energy-efficient, helping to meet new building codes and reduce long-term energy costs for clients.

Aesthetically, these fixtures offer a clean, modern look that blends seamlessly into ceilings, making them ideal for both residential and commercial spaces. Available in various sizes, color temperatures, and finishes, they can be tailored to suit any design vision.

Furthermore, it’s clear why LED downlights have become the preferred lighting fixtures.

Understanding Recent Building Adoptions & LED Downlights

As the popularity of these fixtures grow, so does their associated life safety hazard.  When an LED downlight is fitted into a fire-resistance rated ceiling/floor assembly, the assembly becomes compromised.

How? In the event of a fire outbreak, the heat and flames melt the lighting fixture – opening a prime pathway for heat, smoke, and flames to spread throughout the structure. This reaction jeopardizes the building and everyone within it.

To combat this hazard, building code officials adopted the following building code. The International Building Code states:

“Penetrations of membranes that are part of a horizontal assembly shall comply with Section 714.4.1.1 or 714.4.1.2. Where floor/ceiling assemblies are required to have a fire-resistance rating, recessed fixtures shall be installed such that the required fire resistance will not be reduced.”

This means that any form of recessed lighting – such as low-profile LED downlights – installed in fire-resistance rated applications must include a properly tested and certified form of passive fire protection. Because of this, passive fire protection manufacturers were tasked with formulating a fire-rated solution, specifically for LED downlights.

The Early Stages of PFP for LED Downlights

Traditionally, contractors would build boxes, composed of fire-rated drywall, around each individual LED downlight.

Often, these fire-rated drywall boxes are not built by specifications – raising the problem of inconsistency in the solutions’ quality. To add on to its inconsistency in quality, fire-rated drywall boxes require additional tedious labor – causing labor expenses to raise significantly.

In the effort to reduce labor and material expenses, PFP manufacturers introduced the fire-rated LED downlight. With its ability to be installed easily and merge two solutions into one, fire-rated LED downlights have become a popular choice for contractors and manufacturers.

As it turns out, many of these fire-rated lights have not been properly tested and certified. Without proper testing and certification, these fire-rated lights become a liability in the protection of the building and its occupants.

Consequently, construction professionals have not found a properly tested and certified fire-rated solution, designed for LED wafer openings.

Introducing Tenmat’s Fire Rated Covers for LED Downlights

Until Tenmat’s LED Downlight Fire-Rated Covers. Formulated with state-of-the-art intumescent technology, Tenmat introduced its FF109-200 and FF109-250 LED Downlight Fire-Rated Covers. These covers were designed to expand and seal off unprotected openings, caused by LED wafers, in the event of a fire.

Effortless Installation

With its lightweight, flexible composition, Tenmat’s Fire Rated Light Covers can easily be retrofitted into pre-existing and new construction jobsites. Their adaptable design ensures compatibility with a wide range of LED downlights, including wafer-style fixtures.

A modern, black, cone-shaped structure with an arched entrance and minimal interior on a white platform.

Certified Fire Protection

Aside from its seamless integration during installation, Tenmat’s FF109-200 and FF109-250 LED Wafer Covers both have undergone rigorous testing by accredited laboratories and are certified for up to 60 minutes of fire protection. Tenmat’s LED Downlight Covers are proven to be a reliable choice for meeting stringent building code standards in residential, commercial, and multi-family buildings.

Additional Key Benefits

  • Flexible intumescent material
  • Tool-free installation
  • Low-Profile Design
  • Retrofitting Capabilities

To Sum It All Up

In today’s fast-paced construction landscape, lighting is no longer just about aesthetics or energy efficiency – it’s about making smart decisions that balance form, function, and most importantly, life safety. Low-profile LED downlights have revolutionized modern lighting design with their sleek appearance, ease of installation, and energy-saving benefits.

However, their integration into fire-rated assemblies introduced a critical safety challenge that couldn’t be ignored. That’s where we, Tenmat, step in.

With the creation of the FF109-200 and FF109-250 Fire-Rated Covers, we have successfully bridged the gap between innovative lighting and passive fire protection. These fire-rated covers offer a tested, certified, a code-compliant solution that ensures LED downlights can be safety installed without compromising the integrity of a fire-resistance rated ceiling assembly.

For architects, engineers, and contractors, this means peace of mind – knowing that their lighting choices not only meet design and performance standards but also uphold the standards of life safety.

Because in construction, every detail matters – and when it comes to life safety, there’s no room for failure.

Designed to Protect.

Two black fire protection cones and a downlight with the text: Passive Fire Protection for LED Downlights.

Discover how passive fire protection for LED downlights plays a key role in protecting our communities.

Where It Begins.

Energy efficiency, aesthetics, and increased life longevity are some of the key reasons why LED wafer downlights have been setting the lighting standards in modern construction practices. From constructing new Type V-A multifamily complexes to upgrading the current lighting system in a boutique hotel, LED downlights have the ability to offer easy installation for contractors, and the aesthetics for architects and developers – the ultimate combo. In addition to the previously mentioned applications, LED downlights can often be found in the following applications:

  • Commercial Spaces: Includes shopping malls, mixed-use buildings, local boutiques.
  • Residential Buildings: Includes multi-family complexes, student housing.
  • Hospitality Spaces: Includes hotels, motels, lodges, inns.

 

With its ability to be installed in renovation jobs and new construction projects, it is critical to ensure that our current and future communities are fully protected from life safety hazards, such as unprotected ceiling openings.

Look up at your ceiling. It’s important.

Frequently, unprotected ceiling openings are one of the most common life safety hazards found in modern construction applications. When a fire-rated ceiling assembly is penetrated by a recessed fixture, such as a LED wafer, the integrity of the ceiling is compromised. In the event of a fire outbreak, the recessed fixtures disintegrate after several minutes, allowing a clear pathway for smoke and flames to maneuver to the next level of an infrastructure.
As a result, the International Code Council has established a building code requirement to ensure that this life safety hazard is properly resolved within our communities. For reference, Section 714.5.2 of the 2021 IBC states:

“Where floor/ceiling assemblies are quired to have a fire-resistance rating, recessed fixtures shall be installed such that the required fire resistance will not be reduced.”

In addition, it is essential to point out that LED wafers are being installed in both existing infrastructures and new construction. Therefore, it is critical to ensure that the unprotected ceiling openings are properly fire-rated, no matter if the infrastructure is previously existing or currently being built.

Exploring Your Options.

As the popularity of LED downlights reaches new heights in modern construction, it was critical that a proper fire-rated solution was developed. One of the recent trending solutions are “fire-rated” lights. These solutions are budget-friendly and offer quick, easy installation for on-site contractors. However, a huge misconception about these solutions is because they are composed of metal – they automatically have a fire-resistance rating for applications where fire-resistance rated assemblies are required. However, this is a false assumption. Even though metal itself offers some firestopping properties – it is a poor insulator and does not mean that a metal-based solution qualifies as a fire-rated solution. In order for any solution to claim they are fire-rated, it needs to be tested and approved by a third-party laboratory.

Another method of properly firestopping a LED “pancake” light is fire-rated drywall boxes. This firestopping method is where gypsum wallboards surround the LED wafers; however, there are several cons of this practice. Fire-rated drywall boxes are known to be associated with high labor savings, which can increase the cost of installation beyond budget limits. One of the main causes for high installation costs is this solution’s inability to be retrofitted into a pre-existing ceiling – meaning the pre-existing ceiling would need to be deconstructed prior to the installation of these solutions. In addition to its high labor costs, fire-rated boxes are not properly fire tested and certified – which defeats the purpose of installing proper passive fire protection measures.

Spec the Best, Specify Tenmat.

Now, all of the previously listed solutions don’t exactly check off all the boxes – so, the pressing question is “Are there any solutions that can check off all the preferred features of a firestopping solution?”. To answer your question, let us introduce you to – Tenmat’s FF109-200 and FF109-250, 1 Hour Fire Rated LED Downlight Covers. Composed with the latest intumescent technology, the FF109-200 and 250 are able to stop heat and flames from spreading to other parts of a building for up to 60 minutes. In addition, ALL of Tenmat’s Firestopping Solutions and Materials are tested through third-party laboratories, UL and Intertek and all certifications can be found on our website.. In addition to its firestopping components, the ultra-flexible nature of the intumescent material allows the cover(s) to get rolled up for easy retrofit, remodel, or new construction installations – ideal for a multitude of construction practices. To learn more about these optimal solutions, please visit the FF109-200 and FF109-350 product pages.

End Notes.

Incorporating passive fire protection measures is crucial for the safety of our communities, both in the present and future. LED downlight fixtures are very popular in modern-day construction, but without proper fire-rated solutions, they pose a great threat to our communities. By specifying solutions, such as Tenmat’s FF109-200 and 250, it is ensured that a building’s ceiling openings are protected – allowing for a fire-resistance rated ceiling’s integrity to be foolproof. If this article didn’t answer all of your questions and concerns, please feel free to contact one of our on-site specialists at +1-800-821-3435 or email us at info@tenmatusa.com.