Resonate Testing supports aircraft fire testing programmes for powerplant components, firewalls, nacelles, fluid systems and equipment installed in designated fire zones, using AC 20-135 guidance and related standards including ISO 2685, RTCA DO-160 Section 26 and SAE AS6826.
Resonate supports aircraft fire testing programmes for powerplant components, firewalls, nacelle structures, fluid systems and equipment installed in designated fire zones. AC 20-135 testing focuses on proving that hardware can resist severe flame exposure while maintaining containment, structural integrity and required function under representative installation conditions.
FAA AC 20-135 provides guidance for demonstrating aircraft powerplant fire protection compliance, including fireproof and fire-resistant components, firewalls, designated fire zones and systems exposed to fire hazards.
Fire resistant: Demonstrates ability to withstand a 2000°F ±150°F flame for at least 5 minutes while maintaining intended function.
Fireproof: Demonstrates ability to withstand a 2000°F ±150°F flame for at least 15 minutes while fulfilling its design purpose.
Representative installation: Test setup should reflect relevant operating conditions, load paths, airflow, pressure, fluids and interfaces.
Evidence generation: Supports certification by recording flame exposure, leakage behaviour, integrity, ignition risk and required function.
Related methods: Programmes may also reference ISO 2685, RTCA DO-160 Section 26 or SAE AS6826 depending on the component and certification route.
Its Not cabin flammability: AC 20-135 powerplant fire testing is focused on survivability, containment, function and not posing additional risk under severe fire exposure.
Shock Testing
Environmental Testing
Humidity Testing
Corrosion and Salt Spray testing
Rain and Water Ingress Testing
Sand and Dust Testing
Ready to plan an AC 20-135 fire testing campaign? Send your requirement, drawings, installation assumptions or certification plan for engineer review and receive guidance on fireproof or fire-resistant classification, setup, instrumentation and evidence requirements.
A successful AC 20-135 fire test starts with a signed, revision-controlled test plan and procedure that clearly defines the test article configuration, installation details, pass/fail criteria, instrumentation requirements, and the exact target location on the unit under test (UUT) where burner calibration and fire exposure requirements are to be demonstrated. Establishing these details before testing helps avoid programme delays, specification disputes, and unnecessary retesting.
Before engaging a test laboratory, define the component description, applicable standard, drawings, mounting arrangement, fluid or pressure conditions, required functionality during exposure, and the specific areas of the test article that must satisfy the fireproof or fire-resistant requirements.
Test conditions aft side cooling airflow, fluid temperatures, pressures, flows or mechanical loading and any changes to these parameters after 5 mins during test
In an aircraft engine nacelle fire, safe outcomes depend on systems working together: fire-resistant components must continue their required function for the applicable exposure period, firewalls and fireproof components must contain the event, and isolation or suppression systems must limit the supply of flammable fluids and control the fire. Certification and development testing provide evidence that these protections perform under representative fire conditions.
Resonate Testing supports aircraft fire, firewall and powerplant-component programmes using FAA AC 20-135 guidance and applicable methods such as ISO 2685, SAE AS6826 and RTCA DO-160 Section 26. Test configurations can reproduce installation factors that influence the result, including orientation, mounting, penetrations, pressure, flow, airflow, leakage, structural loading and required function. The test plan, method and acceptance criteria should always be agreed against the aircraft certification basis and the component’s intended installation.
| Standard / Guidance | Primary Focus | Typical Relevance |
|---|---|---|
| FAA AC 20-135 | Aircraft powerplant fire protection and fire testing | Guidance for demonstrating aircraft powerplant fire protection compliance. |
| ISO 2685 | Fire resistance testing of aircraft components | Environmental fire testing for aircraft components and structures in designated fire zones. |
| RTCA DO-160 Section 26 | Fire and flammability testing of airborne equipment | Fire and flammability qualification for aircraft equipment categories. |
| SAE AS6826 | Aircraft engine / powerplant fire-test methods and procedures | Standardise flam fire test guidance for powerplant components and associated equipment |
| Customer/ Airframer specifications | Programme-specific fire and flammability requirements | Standard flame fire-test guidance for powerplant components, used with the applicable certification basis and agreed acceptance criteria. |
Testing performed in support of AC 20-135 is intended to demonstrate whether aircraft powerplant components, installations or assemblies can withstand severe flame exposure while maintaining containment, structural integrity and required function. Typical objectives include assessing flame penetration, backside ignition, leakage, deformation, seal performance and post-exposure condition.
Test planning is normally based on the specific component, certification basis and installation assumptions, including fireproof or fire-resistant duration, burner calibration, orientation, pressure or flow conditions, instrumentation, functional checks, observations and reporting expectations.
Resonate supports engineer-led fire testing for aircraft powerplant components, nacelle structures, firewalls, firewall penetrations, fluid systems, electrical equipment and other hardware exposed to designated fire-zone hazards. Programmes can be planned around AC 20-135 guidance, ISO 2685, RTCA DO-160 Section 26 or customer-defined certification requirements.
Typical campaigns assess flame penetration resistance, cold-side ignition risk, leakage containment, structural integrity and continued function where the component must remain operative during or after exposure. Setup is reviewed against the intended installation rather than treated as a generic burn test.
Successful AC 20-135 testing requires more than achieving a nominal flame temperature. Monitoring and verification may include burner calibration, thermocouple data, pressure or flow conditions, leakage observations, functional checks, pre-test inspection and post-test evidence. Acceptance criteria and abort conditions should be agreed before the campaign begins.
For firewalls, ducts, pipes, valves, electrical enclosures and composite structures, the mounting approach is central to the quality of the evidence. Interface drawings, orientation, penetrations, seals, fluid state, airflow and instrumentation access should be reviewed early.
Early engagement helps identify whether the test should demonstrate fire-resistant or fireproof performance, what function must be maintained, and which installation conditions need to be represented.
| Specification | Capability |
|---|---|
| Classification | Fire resistant or fireproof, based on the applicable requirement |
| Flame Exposure | 2000°F with duration defined by the required classification |
| Fire-Resistant Duration | Typically at least 5 minutes while maintaining intended function |
| Fireproof Duration | Typically at least 15 minutes while fulfilling the design purpose |
| Representative Conditions | Mounting, orientation, pressure, fluid flow, airflow, load and installation interfaces where relevant |
| Components | Firewalls, nacelles, ducts, valves, fuel and hydraulic systems, electrical enclosures, seals and penetrations |
| Monitoring | Burner calibration, thermocouples, pressure or flow data, leakage observations and functional checks |
| Pass/Fail Evidence | Flame penetration, backside ignition, leakage, containment, structural integrity and required function |
| Standards | AC 20-135, ISO 2685, RTCA DO-160 Section 26, SAE AS6826 or customer-defined requirements |
| Test Planning Support | Requirement review, setup planning, instrumentation, safety controls, observation points and reporting scope |
Plan: Review the certification basis, component function, applicable standard, fireproof or fire-resistant classification and acceptance criteria.
Prepare: Confirm fixtures, burner configuration, instrumentation, pressure or flow conditions, safety controls and required functional checks.
Mount and instrument: Install the hardware in a representative orientation and verify thermocouples, controls, fluid connections and observation points.
Calibrate and pre-check: Confirm flame temperature, burner position, operating conditions and pre-test condition of the article.
Expose: Apply the agreed fire exposure for the required duration, such as 5 minutes for fire resistant or 15 minutes for fireproof performance.
Observe: Monitor flame penetration, leakage, backside ignition, structural integrity and required function during or after exposure.
Review and report: Compile achieved conditions, observations, photographs, measurements and pass/fail evidence against the agreed criteria.
Component description, drawings, materials and intended installation location
Applicable standard, certification basis and customer specification
Fireproof or fire-resistant classification and required exposure duration
Mounting orientation, interfaces, penetrations, seals and fixture requirements
Pressure, fluid flow, airflow, mechanical loading or operating conditions to represent
Instrumentation needs, thermocouple locations and observation points
Functional checks required during or after exposure
Fuel, oil, hydraulic fluid, pressure, hazardous material or stored-energy safety information
Acceptance criteria for penetration, ignition, leakage, containment and function
Reporting, photographic evidence and witness requirements
Fireproof means the component can withstand a 2000°F ±150°F flame for at least 15 minutes while fulfilling its intended design purpose.
Fire resistant means the component can withstand a 2000°F ±150°F flame for at least 5 minutes while maintaining its intended function.
A designated fire zone is an aircraft area where fire hazards must be considered, such as engine compartments, nacelles, powerplant installations and related systems.
A firewall is a fire-protection barrier intended to prevent flame, heat or hazardous effects from spreading beyond the protected zone.
Flame penetration occurs when flame passes through, around or beyond the test article in a way that compromises the protected side or installation.
Backside ignition is ignition on the protected or cold side of the article, away from direct burner exposure.
A representative setup reflects the real installation as far as practical, including orientation, mounting, interfaces, penetrations, airflow, pressure and fluid conditions.
For aircraft powerplant fire testing, the concern is often what happens behind or beyond the flame-facing surface. A component may need to prevent flame penetration, avoid cold-side ignition, control hazardous leakage and maintain a required function while exposed to fire.
Containment risk should be reviewed early if the hardware includes fuel, oil, hydraulic fluid, seals, joints, penetrations, pressure boundaries, wiring, composite structures or insulation. The test plan should define how leakage, ignition, deformation and post-test condition will be observed and reported.
Aircraft components often need more than one qualification activity. Coordinating fire, vibration and environmental testing within one campaign helps reduce handover friction, align fixtures and documentation, and keep the engineering review connected across the full programme.
For projects that also need mechanical or environmental testing, review the related services before finalising the campaign sequence, evidence requirements and certification package.
Outputs are agreed before the test so the evidence matches the certification need. A typical package may include:
Recorded flame calibration pre and post test, temperature and BTU (test plan dependant), any UUT telemetry such as pressure, flow and agreed functional data
Evidence showing achieved fire exposure, duration, burner setup and monitoring points
Observations from setup, test execution and post-test review
Photographic evidence of the setup, exposure and post-test condition where agreed
Confirmation of required functional checks completed during or after exposure
An agreed test report or data pack aligned to the acceptance criteria and quotation scope
Book fire testing for aircraft powerplant components, firewalls, nacelle structures, fluid systems and equipment installed in designated fire zones. Use the contact route to share the requirement, drawings, installation assumptions or certification plan for review.
Whether you’re looking to contact us for the first time or have another testing requirement, we’d love to hear from you.
