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SummaryIn the present study, the structural analysis of a three‐parted steel door during a fire resistance test was examined by FEM simulation. The structural analysis is part of a coupled CFD/FEM simulation approach developed for the prediction of fire resistance tests. The basis of this follow‐up work was the calculated temperature in the test specimen from CFD to predict the thermal stresses, deformation and gap formation between the door parts. The spatial information of the temperature in the test specimen was exported. Subsequently, the thermal expansion of the door and the resulting stresses and gaps were calculated. To validate the FEM simulation, the deformation of the steel door was observed. It was found that the simulation predicted the deformation of the steel door in close accordance to the measurement. The maximum displacement was found in the centre of the construction with 141 mm, whereas the simulation predicted a value of 133 mm. In addition to the deformation of the door, also the prediction of the gap formation was validated against the flue gas leakage. The first flue gas exit occurred already after 120 seconds, which was in spatial and temporal conjunction with the maximum gap predicted in the simulation.

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Summary In the present two‐parted study, a numerical approach is shown to consider fire resistance tests in virtual space, including the combustion, thermal analysis of the test specimen, and the deformation process. This part is dealing with the combustion process and thermal analysis of different building materials tested in a fire resistance furnace. Instead of using coupled computational fluid dynamics (CFD)/finite element method simulation for the combustion and thermal heat conduction in the solid, which is commonly used in literature, the present approach considers these transport phenomena in one CFD simulation. This method enables a two‐way coupling between the gas phase and the solid material, where chemical reactions and the release of volatile components into the gas phase can occur (eg, release of water vapour from gypsum). To validate the numerical model, a fire resistance test of a steel door, which is a multilayer construction, and a wall made of gypsum blocks were experimentally and numerically investigated. Due to the chemical reactions inside the gypsum, water vapour is released to the gas phase reducing the flue gas temperature about 80 K. This effect was taken into account using a two‐way coupling in the CFD model, which predicted temperatures in close accordance to the measurement.