Patent / U.S. Patent Registration No. 7,627,999 B2
UL and ULC fire rated suspended and
gypsum ceiling designs require that
penetrations be protected.
Items such as recessed light fixtures,
HVAC diffusers & speaker high hats must
be protected with specified materials.
Historical protection methods include the
construction of a box using fire rated
ceiling tile or rated gypsum board.
2006 International Building Code
718.104.22.168 Membrane penetrations.
Penetrations that are part of a fire
resistance-rated horizontal assembly shall
comply with Section 722.214.171.124.1 or
7126.96.36.199.2. Where floor/ceiling
assemblies are required to have a
minimum 1-hour fire-resistance rating,
recessed fixtures shall be installed such
that the required fire resistance will not be
Typical Detail, UL P202 - 1hr.
14A. Alternate Fixture Protection — Batts and Blankets* — 1-1/4 in. thick, cut
into pieces to form a five sided enclosure, trapezoidal in cross-section, approx 1/2 in.
longer and wider than the fixture and the enclosure. Pieces held together by 18 SWG tie
wire. THERMAFIBER INC.
Alternate Fixture Protection
Most UL suspended and gypsum fire
rated ceiling designs list Thermafiber
insulation board as a ceiling fixture
Patented SafeLite covers are
fabricated from UL Labeled
Thermafiber board at 1 ¼” thick to
satisfy listing requirements.
UL file R-4643 / US & Canada
Thermafiber Used exclusively in SafeLite Fabrication
SafeLite (Thermafiber) Covers
Thermafiber board is classified by Underwriters
Laboratories Inc. and ULC for use in 48 designs of
fire rated floor and roof-ceiling assemblies listed
below. (Ref. BXUV prefix for UL/US or BXUV7 for UL
34 Floor Designs: A003, D010, 209, 216, 219, G007,
008, 036, 202, 204, 211, 213, 215, 222, 227, 228, 230,
231, 234, 252, 258, 268, 523, 526,547, J201, 202,
L005, 006, 202, 206, 530, 541, and 591.
14 Roof-ceiling Designs: P202, 203, 207, 213, 214,
228, 229, 230, 235, 237, 242, 246, 257, and 267.
Listings include: concrete on steel deck with bar
joist or beam, formed or precast deck, wood floor
systems and roof / ceiling assemblies.
SafeLite Board is manufactured from
up to 90% recycled content.
UL Batt & Blanket field
constructed options include:
3 - 5 sided box or 4 - 6 sided tent shaped enclosure.
As shown in several UL listed designs, light enclosures
may be vented.
Thermafiber material is listed at 1 ¼” thick with 1”
typical fixture air space.
SafeLite kits are fabricated exclusively with 1 ¼”
Thermafiber board to satisfy the listing criteria.
SafeLite’s patented quick fold cover and attachment
method provides a fast and easy installation.
SPI’s patented SafeLite maintains ceiling fire
ratings, and provides documented acoustical
performance that improves sound blocking or
speech privacy and can provide energy savings.
Standard Fluorescent Light Dimensions
3 5/8” 4 5/8”
Standard SafeLite fluorescent covers are available 24 and 48” long.
Other fluorescent and can light sizes are made to order.
Maximum service temperature: 1200F
Melt Point: > 2000F
Non-combustible per ASTM E-136
Flame Spread 25, Smoke 0 per ASTM E-84
R Value 4.2 per inch per ASTM C-518
(effective R value 5.25 at 1 ¼” thick. helps
reduce heating/cooling energy costs)
Acoustical Performance per ASTM C-423
NRC 1.00 at 2” thick, CAC data follows
Ceiling Attenuation Class (CAC)
CAC is important and controls sound
transmission and speech privacy
between closed adjacent spaces.
Common applications include:
– Office spaces and corridors
– Closed office, conference rooms
– Mixed plan offices
– Classrooms and music rooms
– Healthcare exam rooms, doctor’s offices
Example, Ceiling CAC Performance
CAC, A measure for rating the performance of a ceiling system as a barrier
to airborne sound transmission through a common plenum between
adjacent closed spaces such as offices.
Ceiling spec. NRC .70, CAC 40
A CAC less than 25 Note: penetrations through
is considered low CAC 40 the ceiling membrane
performance. * increase noise transmission
to adjacent space and floors
* Suspended or
Wall w/ R11
STC = 44
Recessed ceiling light, speaker, HVAC diffuser and sprinkler penetrations
significantly impact CAC performance.
CAC – Two Room Transmission Loss –
AL20 (TM418) ASTM E 1414
Armstrong high CAC Armstrong #1811 tile
#1811 Fine Fiss. tile with 2 – 2 x 4 fixtures
without light with SafeLite covers.
fixtures, CAC 44 CAC 45
Armstrong #1811 tile
with 2 – 2 x 4 light
fixtures, CAC 41
Conclusion: Just 2 uncovered light fixtures had a significant impact on the
acoustical performance of a ceiling.
The 4 db (decibel) CAC improvement shown with SafeLite is significant.
A 3 db change sounds as if the noise level was reduced by 50%.
This type of documented performance is critical for any sound proofing effort.
A typical high performance acoustical ceiling with
numerous penetrations (not uncommon for
penetrations to make up 10 - 20% of the ceiling area.)
SafeLite covers restore ceiling sound blocking (CAC) performance.
Items such as recessed lights, speakers, HVAC diffusers, sprinkler
heads etc. significantly compromise ceiling performance.
SafeLite Can Light Covers for
Architect specified SafeLite covers to block sound from
lower level retail and restaurants to second floor office
and third floor apartment space.
A thermal ceiling scan reveals missing insulation.
Uninsulated recessed light fixtures represent areas of
energy loss. SafeLite can reduce these losses.
1 ¼” thick SafeLite light covers
provide an R Value of 5.25.
2009 IECC Mandatory
Requirements – Recessed
All recessed luminaires installed in the building envelope
* Type IC rated and sealed with gasket or caulk between housing and interior wall or
* Type IC rated and labeled in accordance with ASTM E 283 to allow ≤ 2.0 cfm of air
movement from conditioned space to ceiling cavity
• “Code establishes the mimium standard” SafeLite provides additional
1) 1 ¼” thick main cover with pre grooved easy fold side panels.
2) End caps
3) Spacer peel and stick insulation pin w/ washer to secure cover and
maintain air space.
4) Insulation pins for end cap attachment.
Contractors report averaging 1 or 2 heavy and awkward drywall or fragile
fire rated tile enclosures can be fabricated and installed per man hour.
SafeLite enclosures are installed on an average of 10 per man hour.
That translates to 80 SafeLite covers per 8 hour day Versus 8 to 16 for tile
or drywall enclosures. This provides an opportunity for BIG labor savings
(one contractor documented $10,000 savings on his first job using
SafeLite versus his previous field fabrication method).
At a rate of 2 drywall or tile covers per hour and a loaded labor rate of
$40/hr. would yield $20 labor cost to field fabricate and install plus the
material cost. Knotching necessary with these covers for hanger wires and
power cable is slow and can result in cover breakage especially on ceiling
it would only cost $4 in labor to install a SafeLite cover which easily slits to
accept hanger wire or power cable and is very durable minimizing call
Using SafeLite frees up skilled labor to perform other job functions.
Other SafeLite Advantages
Precise factory pre-fabricated kits typically
yield a better quality enclosure than field
cut and assembled methods.
SafeLite covers are more durable than
field constructed ceiling tile covers that
simply don’t hold up.
Peel and stick insulation pins keep
SafeLite in position on the light fixture.
Congested plenum space is not as critical
for installation access with lightweight,
flat SafeLite panels.
Ceiling Plenum Space
At 1 ¼” thick SafeLite covers are
easier to install in congested ceiling
cavity areas then field constructed.
Acoustical ceiling and drywall contractors
General contractors that self perform
Institutional facilities, especially
maintenance departments at hospitals and
Modular construction factories
Firestop specialty contractors
Fire protection &
SafeLite Ordering Information
Typical lead time 7 -10 days ARO
on back of
Without recessed light fixture protection, no
fire rating is achieved on either suspended or
drywall ceiling designs. Therefore significant
potential liability exists for non compliance
to code or UL design listings.
SafeLite kits also offer enhanced ceiling
acoustical and thermal performance.
Fig. 1 A standard SafeLite 2 x 4’ light
fixture main panel cover. Dashed lines
represent V groove mitered corners.
Fig. 2 SafeLite main panel
with side panels folded down.
Fig. 3 End flaps folded back in
position over light fixture.
Mark and carefully slit for hanger
wires and power cable as needed.
Fig. 4 SafeLite in position on fixture
with end flaps tucked into grid and lock
washers secured to offset anchor pins.
Fig. 5 Section detail of offset
anchor pin, fixture airspace and lock washer.
Fig. 6 Detail of offset peel and stick
anchor pin and lock washer. Note: Snip off
excess pin length to prevent injury
(See Fig. 8 for Alt. spacer clip detail).
Fig. 7 Completed installation with
end caps (5 sided kits) installed
using 3 - 4.5” MC pins per end cap
spaced as shown. Note: check the
specific UL listing for ventilation
opening requirements on light
fixture applications and cut in as
Fig. 8 An alt. “V” spacer clip is
slipped over a straight stick pin
replacing the offset spacer pin to
maintain the 1” airspace.
SafeLite Installation Summary
1) For existing ceiling applications, remove ceiling tile from both sides
and ends of the light fixture to aid installation otherwise skip to step 2.
2) Install the Peel N Stick “S” pins on a clean fixture top, approximately
6” from each end of a 2’ X 4’ light fixture or one pin at about the center of
a 2’ x 2’ fixture. Note: Keep pins away from the light ballast mounting
3) Fold long side panels up so that facing paper meets facing.
4) Slide SafeLite through ceiling grid and position over the fixture foil
5) Fold side panels down to create a 3 sided box.
6) Position SafeLite square over the fixture aligning the end of the cover
with the end of the fixture and carefully impale onto the “S” pin(s)
tucking side panels inside the grid on both sides of the fixture.
7) Carefully slit SafeLite to accommodate fixture support wires and
power cable as necessary for cover installation.
8) Carefully push insulation lock washer(s) down over “S” pin(s) and snip
off excess to prevent injury.
9) Position end caps against SafeLite, foil side out, flush with the cover top
and secure to panel top center point using straight push pins at the center.
Secure each cap panel end to the long side panel edge with additional
10) Cut ventilation slots as necessary to meet any specific UL listing and
prevent fixture ballast from overheating.
11) Replace any tiles that were removed during SafeLite installation.
SPI recommends first time users consult with the
project Architect and local Building Inspector prior to
purchase and installation.