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40-527: Starlite is an intumescent material said to be able to withstand and insulate from extreme heat. It was invented by British hairdresser and amateur chemist Maurice Ward (1933–2011) during the 1970s and 1980s, and received significant publicity after coverage of the material aired in 1990 on the BBC science and technology show Tomorrow's World . The name Starlite was coined by Ward's granddaughter Kimberly. The American company Thermashield, LLC, says it acquired

80-568: A National Audit Office report found that costs had increased by £1.07 billion to £1.8 billion and completion date had slipped to 2023. Construction was begun before design had been finalised and risk was not shared with contractors, so they were not incentivised to control costs. In November 2020, it was announced that the Ministry of Defence had triggered a contractual break point and would take ownership of AWE Plc in July 2021. Sir John Manzoni

120-735: A 25‑year contract (until March 2025) to operate AWE, although all the sites remained owned by the Government of the United Kingdom which had a golden share in AWE plc. In November 2020, it was announced that the Ministry of Defence had triggered a contractual break point and would take ownership of AWE Plc in July 2021. The establishment is the final destination for the Campaign for Nuclear Disarmament 's Aldermaston Marches march from Trafalgar Square , London . The first Aldermaston March

160-405: A bare hand, even after five minutes in the flame of an oxyacetylene blowtorch . It would also prevent a blowtorch from damaging a human hand. When heat is applied, the material chars , which creates an expanding low density carbon foam which is very thermally resistant . Even the application of a plasma torch , capable of cutting eighteen-inch thick steel plate, has little impact on Starlite. It

200-402: A fire broke out in the explosives processing area at AWE Aldermaston, resulting in the evacuation of nearby residents from their homes. Investigations by a local newspaper revealed that from 1 April 2000, to 5 August 2011, 158 fires broke out at AWE sites, with the fire brigade being called out to deal with alarms on average four times a week over this period. The Health and Safety Executive took

240-485: A lot of evaluation and … we know all the tremendous possibilities that this material has." Boeing , which was the main contractor for the Space Shuttles in 1994, became interested in the potential of Starlite to eliminate flammable materials in their jets. By the time of Ward's death in 2011 there appeared to have been no commercialisation of Starlite, and the formulation of the material had not been released to

280-490: A material said to be thermal proof, it is said to be not entirely inorganic but up to 90 per cent organic . Nicola McDermott, Ward's youngest daughter, stated that Starlite is 'natural' and edible , and that it has been fed to dogs and horses without ill effects. The American company Thermashield, LLC, which owns the Starlite formula, stated in a radio interview that Starlite is not made from household ingredients and there

320-399: A matrix formed by the molten binder which is typically based on vinyl acetate copolymers or styrene acrylates . Ablative coatings contain a significant amount of hydrates . When the hydrates are heated, they decompose, and water vapour is released, which has a cooling effect. Once the water is spent, the insulation characteristics of the char that remains can retard heat transfer through

360-663: A troop carrier (C‑47) group base, and was assigned USAAF station No 467. In 1952, the High Explosive Research project was renamed the Atomic Weapons Research Establishment (AWRE), with William Penney appointed as the first director. In 1954 AWRE was transferred to the newly created United Kingdom Atomic Energy Authority (UKAEA). In 1971, under the provisions of the Atomic Energy Authority Act 1971 ,

400-461: Is a closely guarded secret. "The actual composition of Starlite is known only to Maurice and one or two members of his family," former Chief Scientific Adviser to the Ministry of Defence Sir Ronald Mason averred. It is said to contain a variety of organic polymers and co-polymers with both organic and inorganic additives, including borates and small quantities of ceramics and other special barrier ingredients—up to 21 in all. Perhaps uniquely for

440-463: Is approximately 1 mile west of the main AWE site. Blacknest's main function is to develop and maintain expertise in using seismic techniques to detect and identify underground explosions. This expertise and the techniques have been used in the past to provide assessments for the UK government on nuclear explosions carried out by other countries. The expertise is to be used as part of Britain's contribution to

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480-507: Is no PVA glue , baking soda or baking powder in it. Ward allowed various organisations such as the Atomic Weapons Establishment and ICI to conduct tests on samples, but did not permit them to retain samples for fear of reverse engineering . Ward maintained that his invention was worth billions. Sir Ronald Mason told a reporter in 1993, "I started this path with Maurice very sceptical. I’m totally convinced of

520-636: Is reliable and safe throughout its intended in-service life. The new facilities and extra supporting infrastructure are required in the absence of live nuclear testing no longer allowed under the Comprehensive Test Ban Treaty . AWE co-operates with the Los Alamos National Laboratory in the United States and other American nuclear weapons laboratories in carrying out subcritical nuclear tests at

560-653: Is the successor to the Atomic Weapons Research Establishment ( AWRE ) with its main site on the former RAF Aldermaston and has major facilities at Burghfield , Blacknest and RNAD Coulport . AWE plc , responsible for the day-to-day operations of AWE, is owned by the Ministry of Defence and operated as a non-departmental public body . Until June 2021, AWE plc was owned by a consortium of Jacobs Engineering Group , Lockheed Martin UK , and Serco through AWE Management Ltd, which held

600-466: The BBC reported that a scientist at AWE, who had worked on Britain's early atomic bomb programme decades before, recognised a small spike at an energy of 803 kilo-electron volts (keV) as the gamma ray signal from polonium-210, a critical component of early nuclear bombs, which led to the correct diagnosis. Further tests using spectroscopy designed to detect alpha radiation confirmed the result. In July 2015

640-563: The International Organization for Standardization (ISO). Intumescent coatings for steel constructions must be approved in standardized fire tests. These intumescent materials produce a light char which is a poor conductor of heat , thus retarding heat transfer. Typically the light char consists of microporous carbonaceous foam formed by a chemical reaction of three main components: ammonium polyphosphate , pentaerythritol , and melamine . The reaction takes place in

680-545: The Nevada underground test site to obtain scientific data to maintain the safety and reliability of nuclear weapons. Subcritical tests are not banned by the Comprehensive Test Ban Treaty on nuclear weapons. The most recent test took place in February 2006. The cost of decommissioning AWE facilities when they become redundant, including nuclear waste disposal, was estimated at £3.4 billion in 2005. On 3 August 2010

720-476: The Office for Nuclear Regulation issued an improvement notice to AWE demanding that it demonstrate that it has a long-term strategy for managing Higher Active radioactive Waste in order to reduce the risk to the public and its employees. In 2011 a project named MENSA to construct a new warhead assembly and disassembly facility at Burghfield had been approved, to be completed in 2017 at a cost £734 million. In 2020,

760-476: The RAFs WE177 freefall nuclear bomb. In 1998 the company suffered two prosecutions for safety breaches, one for discharge of tritium into a nearby stream and another for an incident where two workers inhaled plutonium . In 1999 Hunting-BRAE lost the contract to AWE Management Ltd (AWE ML), a consortium of BNFL , Lockheed Martin and Serco . AWE ML's subsidiary, AWE plc , assumed responsibility for

800-443: The base. The MoD said that security was never threatened, but MoD police considered it a "critical" incident. Six officers were dismissed for gross misconduct and 25 resigned. Formerly part of the Ministry of Defence , AWE Blacknest has, for over 40 years, specialised in forensic seismology , researching techniques to distinguish the seismic signals generated by underground nuclear explosions from those generated by earthquakes. It

840-407: The continued undertaking of operations in ageing facilities due to delays to the delivery of modern standard replacement facilities." The ONR anticipated AWE would move back to normal regulatory attention in 2021 after the new facilities are completed. Scientists at AWE were involved in testing for radioactive poison after the poisoning of Alexander Litvinenko . No gamma rays were detected; however,

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880-476: The decision to prosecute AWE plc on three charges relating to health and safety after their investigation into the fire in 2010, the first hearing in this case being held on 6 August 2012. On 16 May 2013 AWE pleaded guilty to a single offence contrary to the Health and Safety at Work Act 1974. In 2013 a whistleblower alerted the authorities to lapses in security caused by misconduct among police officers guarding

920-411: The fire stop assembly. Soft char products are typically used in thin film intumescent materials for fireproofing protection of structural steel as well as in firestop pillows . Harder char is produced with sodium silicates and graphite . These products are suitable for use in plastic pipe firestops in which applications it is necessary to exert expansion pressure to fill the gap left in

960-467: The insulating layer. Materials scientist Mark Miodownik described Starlite as a type of intumescent paint , and one of the materials he would most like to see for himself. He also admitted some doubt about the commercial potential of Starlite. Its main use appears to be as a flame retardant . Testing of modern composite materials enhanced with Starlite could expand the range of potential uses and applications of this substance. Starlite's composition

1000-470: The intumescent properties. Some intumescent materials are susceptible to environmental influences such as humidity, which can reduce or negate their ability to function. Atomic Weapons Establishment The Atomic Weapons Establishment ( AWE ) is a United Kingdom Ministry of Defence research facility responsible for the design , manufacture and support of warheads for the UK's nuclear weapons . It

1040-419: The middle of the fire stop assembly left by the melting plastic pipe. Intumescent coatings may be designed for protection of metals from fire, such as structural steel . Reviews of the technology are available. They may be based on a number of resin binders including epoxy , and silicone. Melamine-formaldehyde resin systems have been used using layered double-hydroxide modified phosphate esters that improved

1080-675: The operation of US nuclear facilities. Lockheed's failings included safety concerns at the Y-12 facility at Oak Ridge, Tennessee , an American weapons plant similar in certain ways to Aldermaston. In December 2008, the BNFL share in AWE Management Ltd was sold to Jacobs Engineering Group , an American engineering services company. Since about 2013 the Office for Nuclear Regulation (ONR) has given both AWE sites enhanced regulatory attention due to "safety and compliance concerns, and

1120-415: The operation of all AWE sites on 1 April 2000. This was not full privatisation as the Ministry of Defence continued to own all the AWE sites as well as a golden share in AWE plc. Critics pointed out that BNFL and Lockheed Martin did not have perfect safety records either. BNFL suffered embarrassing revelations of falsified quality checks in nuclear fuels and Lockheed was the subject of scathing reports on

1160-578: The other ROFs, which were then formed into a government-owned defence company, Royal Ordnance plc and was privatised in 1987. ROF Burghfield and ROF Cardiff remained within the Procurement Executive and came under the control of AWRE. In 1987, AWRE was combined with ROF Burghfield and ROF Cardiff to form the Atomic Weapons Establishment (AWE), these sites being renamed AWE Burghfield and AWE Cardiff (the latter

1200-509: The production activities of UKAEA were transferred to the newly created British Nuclear Fuels Ltd. (BNFL). In 1973 AWRE was transferred to the Procurement Executive of the Ministry of Defence , see Atomic Energy Authority (Weapons Group) Act 1973 . Parts of AWRE's weapons production processes were carried out at two Royal Ordnance Factories (ROFs): ROF Burghfield and ROF Cardiff. In 1984 these two ROFs were separated from

1240-414: The public. A YouTube user, NightHawkInLight, attempted in 2018 to create materials that replicated the properties of Starlite. Observing that the mechanism that generates an expanding carbon foam in Starlite is similar to black snake fireworks , NightHawkInLight concocted a formula using cornstarch , baking soda , and PVA glue . After drying, the hardened material creates a thin layer of carbon foam on

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1280-452: The reality of the claims." He further states, "We don't still quite understand how it works, but that it works is undoubtedly the case." NASA became involved in Starlite in 1994, and NASA engineer Rosendo 'Rudy' Naranjo talked about its potential in a Dateline NBC report. The Dateline reporter stated that Starlite could perhaps help with the fragile Space Shuttle heat shield. Naranjo said of their discussions with Ward, "We have done

1320-650: The replication recipe failed when it was used to make a crucible for an induction furnace . Intumescent The details for individual building parts are specified in technical standards which are compiled and published by national or international standardization bodies like the British Standards Institute (BSI), the German Institute for Standardization (DIN), the American Society for Testing and Materials (ASTM) or

1360-543: The rights to Starlite in 2013 and replicated it. It is the only company to have itself publicly demonstrated the technology and have samples tested by third parties. Thermashield's Starlite has successfully passed femtosecond laser testing at the Georgia Institute of Technology and ASTM D635-15 Standard Testing. Live demonstrations on Tomorrow's World and BBC Radio 4 showed that an egg coated in Starlite could remain raw, and cold enough to be picked up with

1400-477: The surface when exposed to high heat, insulating the material from further heat transfer. He later improved it by taking out the PVA glue and baking soda, and adding in flour, sugar and borax. Using borax and flour makes it less expensive, mold and insect resistant, and able to work when dry. Several experiments testing the replication and variant recipes show that they can handle lasers, thermite , torches, etc. But

1440-408: Was announced as chair-designate, and he formally took on the role of chair of the board on 1 July 2021. AWE is tasked to help the United Kingdom maintain a credible and effective minimum nuclear deterrent: A significant programme of investment took place over the three-year period from 2005 to 2008, of about £350 million per year, to provide assurance that the existing Trident missile warhead

1480-450: Was closed in 1997). It remained with the Ministry of Defence, Procurement Executive. However, in 1989, the UK government announced its intention to find a suitable private company to run AWE under a Government Owned/Contractor Operated (GO‑CO) arrangement. In 1993 the government awarded a contract to Hunting-BRAE, a consortium of Hunting Engineering , Brown and Root and AEA Technology . During Hunting-BRAE's management AWE decommissioned

1520-639: Was conceived by the Direct Action Committee and took place in 1958. The British nuclear weapons programme, then operating under the project name ' High Explosive Research ' within the Ministry of Supply , established operations on 1 April 1950 at the former RAF Aldermaston airfield. The airfield was constructed in World War II and had been used by the Royal Air Force and the United States's Eighth and Ninth Air Force as

1560-442: Was due to particle scatter of an ablative layer, thereby increasing the reflective properties of the compound. Testing continues for thermal conductivity and capacity under different conditions. Starlite may become contaminated with dust residue and so degrade with use. Keith Lewis, a retired MOD officer, noted that the material guards only against thermal damage and not the physical damage caused by an explosion , which can destroy

1600-491: Was reported that it took nine seconds to heat a warhead to 900 °C, but a thin layer of the compound prevented the temperature from rising above 40 °C. Starlite was also claimed to have been able to withstand a laser beam that could produce a temperature of 10,000 °C. Starlite reacts more efficiently as more heat is applied. The MOD's report, as published in Jane's International Defence Review 4/1993, speculated this

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