Passive Fire Protection:
Intumescent Coatings
oday most buildings and structures have some degree of fire protection in order to
T JPCL Staff
protect lives, delay possible structural collapse allowing for evacuation, provide areas
of temporary refuge in the case of fire, and ensure the integrity of escape routes by
preventing or delaying the escalation of a fire and protect high-value assets.
There are two basic types of fire protection: active and passive. Active fire
protection includes alarms and detection systems, sprinklers and water deluge systems,
firefighting equipment and foam and powder extinguishers. Passive fire protection involves
components of structural methods and materials such as concrete, mineral fiber boards,
vermiculite cements and intumescent coatings. This article will describe how intumescent
coatings can achieve passive fire protection in many structure types including offshore
constructions, ships and commercial buildings.
52 JPCL September 2014 / paintsquare.com
©iStockphoto/Gordo25
All other images courtesy of The Sherwin-Williams Company
1,200
Hydrocarbon Heating Curve
Uncoated Steel
1,000
800
Temperature (C)
600
400
Intumescent Coated Steel
200
0
0 10 20 30 40 50 60 70
Time (minutes)
Fig. 1: This graph illustrates the effect of intumescent coating on steel temperature
in a hydrocarbon fire.
Comparison of Standard Fire Test Heating Regimes
1,200
1,000
Intumescent coatings have been used
800
to protect the steelwork in buildings and
600
other structures from fire for
Temperature (C)
approximately 40 years. These coatings
work by swelling up in the event of fire 400 BS 476 Cellulosic Fire Heating Regime
and physically creating a barrier between ASTM E119/UL 263 Cellulosic Fire Heating Regime
BS 476 Hydrocarbon Fire/NPD Heating Regime
the steel and the fire for up three hours. 200
Steel loses its structural strength at about
0
500 C and these coatings can delay the 0 20 40 60 80 100 120
Time (minutes)
time it takes to reach this temperature
(Fig. 1). Intumescents are often referred Fig. 2: This graph compares the heat-up rate of cellulosic and hydrocarbon fires.
paintsquare.com / JPCL September 2014 53
PASSIVE FIRE PROTECTION: INTUMESCENT COATINGS
to as thin-film or thick-film coatings. Thin-film intumescents can be
solvent- or water-based products and have dry film thicknesses
(DFTs) of less than 5 millimeters. Thick-film coatings are typically
solvent-free, epoxy-based with DFTs of up to 25 millimeters. Thick-
film epoxies can also be used to form castings, typically in two half-
shells to protect narrow diameter pipework where spraying would
create large volumes of overspray.
The acceptance and use of intumescent coatings increased
dramatically in Europe in the 1970s as the major oil companies
learned of their ability to protect structural steel from the extreme
heat caused by hydrocarbon fires, including jet fires caused by
leaking hydrocarbons.
In 1988 an explosion and subsequent oil and gas fires at the
Piper Alpha, a North Sea oil production platform, resulted in the
deaths of 167 people and £1.7 billion ($3.4 billion) in damage. The
severity of this disaster, considered the worst offshore oil disaster
at the time, prompted increased development and use of
intumescent coatings for protection against hydrocarbon fires. The
coatings developed tended to be thick-film coatings, often with
mesh reinforcement.
Also, in the 1980s, exposed steel was used more prevalently in
the design of commercial structures and high-rise build-ings,
increasing the use of thin-film intumescents which looked more like
con-ventional paint and therefore could meet the aesthetic
requirements of architects.
How Do Intumescent Coatings Work?
Intumescent coatings react to fire by expanding to form a carbon
“char” with low thermal conductivity, which essentially forms an
insulating layer reducing the rate of heat transfer and extending the
time necessary to reach the critical failure temperature of the
underlying steel.
It’s a complex chemistry incorporating the organic (coating)
binder resin — typically an epoxy — and an acid catalyst, for
example ammonium polyphosphate, which decomposes to yield a
mineral acid. This acid reacts with a carbonific source, for example,
pentaerythritol, to produce a carbon char. A spumific (foam-
producing) agent, such as melamine, reacts with the acid source
and decomposes, evolving into an inert gas which then expands the
char. These are the basic reactions taking place, although more
complex interactions also occur. For example, filler particles are
incorporated into the formulation to act as nucleating sites or
“bubble growth” sites and the resin binder plays a large part in
Fig. 3: These images show the progression of a typical jet fire test
using ISO 22899-1. softening and charring. Reinforcing mesh can be used to support
the formed char.
54 JPCL September 2014 / paintsquare.com
Click our Reader e-Card at paintsquare.com/ric
PASSIVE FIRE PROTECTION: INTUMESCENT COATINGS
Cellulosic vs. Hydrocarbon Fires and structures” and EN 13381 (part 8), restoration afterwards. Poor durability can
A cellulosic fire has a fuel source “Test methods for determining the also lead to corrosion of the substrate,
composed mainly of cellulose — for contribution to the fire resistance of compromising structural integrity. To ensure
example, wood, cardboard or paper. structural members” describe how durability of intumescent coatings the key
Hydrocarbon fires are fueled by intumescent coatings are tested with ingredients — ammonium polyphosphate,
hydrocarbon compounds and ignite and cellulosic fire exposure. Performance melamine and pentaerythritol — are all
grow exceedingly fast, achieving high depends on coating thicknesses, the types sensitive to moisture and must be
temperature almost immediately after of steel section, I sections, hollow sections formulated carefully.
ignition, greater than 1,000 C in less than and the section orientation, i.e., beam or Different resins are used to formulate
five minutes (fig. 2, p. 53). Cellulosic fires column. intumescent coatings for different
are slower to reach maximum temperature Thermocouples are used to measure applications. Water-based acrylic materials
but may eventually reach or surpass the furnace temperature and core steel are formulated for use in mainly dry, internal
temperature of a hydrocarbon fire. temperature. Other test standards include locations. Solvent-based acrylic materials are
used to formulate intumescent coatings for
use in internal or sheltered external
Table 1: Ratio of Surface Exposed to Fire and "Heat Sink"
locations. Solvent-based or solvent-free
Hp/A (m-1) A/V (m-1) epoxy materials are used to formulate
intumescents that can be used in any
location. These resins have different
Heated perimeter Surface Area
weathering performance, and therefore,
Cross section Area Volume protection capabilities.
Perimeter in m Surface Area in m2
To test the durability of an intumescent
Cross section area in m2 Volume in m3
coating, standard coating test procedures
are used such as NORSOK M 501, “Surface
(per linear meter) preparation and protective coating,”
Underwriters Laboratory, UL 1709, “Rapid
Hydrocarbon fires can reach UL 1709, “Rapid Rise Fire Tests of Rise Fire Tests of Protection Materials for
temperatures higher than 1,000 C in less Protection Materials for Structural Steel” for Structural Steel” and European Technical
than five minutes (Fig. 2, p. 53). A pool hydrocarbon fire exposure, ISO 22899-1, Approval Guidance, ETAG 18-2, “Reactive
(hydrocarbon) fire is defined as a turbulent “Determination of the resistance to jet fires Coatings for Fire Protection of Steel
diffusion fire burning above a horizontal of passive fire protection materials” and IMO Elements.”
pool of vaporizing hydrocarbon fuel where Resolution A.754 (18), “Recommendation on In addition, the intumescent coating should
the fuel has zero or low initial momentum. A Fire Resistance Tests for ‘A,’ ‘B’ and ‘F’ Class not spall or crack in use, be resistant to
jet fire is a turbulent diffusion fire resulting Divisions” for fire protection of decks, atmospheric and chemical attack and be
from the combustion of a fuel continuously bulkheads and doors on marine vessels. It is recoatable with itself — even after prolonged
released with high pressure. not possible to test every variation, so the curing. There should also be excellent
test results are analyzed to produce an bonding between substrate, primers and the
Testing Intumescent Coatings assessment of performance. intumescent to combat the problems of
No two fires are the same. The conditions under-film corrosion.
depend on the type and quantity of fuel, the Ensuring Durability
availability of oxygen and ambient To protect steel in a fire a coating must be Specifying Fire Protection
conditions. For reproducible product testing resistant to the environment and be intact at Firstly, the item to be protected must be
in the U.K. “standard” fires have been the time of the fire. Poor durability can lead identified, whether it is structural steel,
defined. British Standards BS 476 (parts 20 to ineffective fire protection resulting in vessels or divisions such as fire-resistant
and 21) “Fire tests on building materials structural failure during a fire and expensive bulkheads or decks on ships. The general
56 JPCL September 2014 / paintsquare.com
Click our Reader e-Card at paintsquare.com/ric
BidTrackerHalf6_Layout 1 9/8/14 10:43 AM Page 1
INDUSTRIAL PAINTING LEADS ON DEMAND
Click our Reader e-Card at paintsquare.com/ric
• Targeted painting leads sent right to your inbox • Searchable database • Plans and specifications
Find work faster with Paint BidTracker, the only lead service designed for the coatings industry.
Try it for FREE today, visit www.paintbidtracker.com/trial to claim your 5-day trial.
Contact Howard Booker at [email protected] or 1-800-837-8303 x 157. Over a Decade of
Quality Painting Leads
paintsquare.com / JPCL September 2014 57
PASSIVE FIRE PROTECTION: INTUMESCENT COATINGS
rule is, the thicker the coating, the longer increase. Lightweight steel sections will heat order to determine the appropriate thickness
the protection – up to a limit. The thickness up faster than heavier sections and will of the coating, taking into consideration the
of the intumescent used will depend on the therefore need more protection for a given shape or shapes of the steel and accounting
weight and type of the steel member being time. for any cutouts or irregularities in the
protected. As the weight 1of 2/11/14
holdtight_island_Layout steel decreases,
9:00 AM Page Rather
1 than just figuring the weight of the beams.
YOU KNOW IT WHEN YOU SEE IT
the thickness of the intumescent should steel, specific calculations must be made in The critical steel temperature which must
be protected against should be defined —
for example, structural steel between 200
and 750 C, vessels between 200 and 350 C,
or a 140 C temperature rise for divisions
where the critical temperature requirement is
much lower to protect personnel on the
other side of the division or in a safety
refuge.
Next the section factor must be
considered, as well as the fire protection
period of between 30 minutes and four
hours. The section factor (Hp/A) is the ratio
of the fire exposed perimeter to the cross
sectional area of the steel (Table 1, p. 56).
Most intumescent coating suppliers
provide guidance in calculating the thickness
of the coating required for a specific use
and some have dedicated departments
Suncor Energy uses HoldTight®102 to remove salts from its FPSO Terranova and other similar staffed with trained fire engineers who will
vessels in the North Atlantic every time it re-coats decks, structural steel, piping and other surfaces
exposed to the sea. do the calculations for you.
Consideration must also be given to the
NO FLASH RUST = A CLEAN SURFACE service environment the structure or vessel
HoldTight
®102 is the standard of performance for preventing flash rust: will be exposed to as well as any special
Q NO SALT. requirements such as blast resistance, high
Removes all contaminants or low substrate temperature or cryogenic
Q NO RUST. spill protection.
Leaves a rust-free surface for 48 hours or more – often 3 to 5 days
Q NO DETECTABLE RESIDUE. Conclusion
There is nothing left on the surface that might interfere with your coating. In addition to offering fire protection for up
Click our Reader e-Card at paintsquare.com/ric
to four hours, intumescent coatings offer
Among rust preventers and salt removers,
speed of application, shop or field
®
HoldTight 102 is the most widely used,
application, aesthetic appearance and ease
reliable, time-proven, lab-tested, field-tested,
recommended and approved by coating of inspection and maintenance.
companies. Intumescents can protect a variety of steel
Contact us today!
International +1 713 266 9339 surfaces from structural columns and
Call, email or visit our website today to see why
1 800 319 8802 cellular beams, to building components,
®
HoldTight 102 is the best option for low-cost, (Toll Free in N. America)
easy-to-achieve, and easy-to-measure
[email protected] vessels and complex shapes. They can be
contaminant-free surface preparation. www.holdtight.com formulated to protect against cellulosic and
hydrocarbon fires including jet fires and fires
resulting from explosions. JPCL
58 JPCL September 2014 / paintsquare.com
Click our Reader e-Card at paintsquare.com/ric
Click our Reader e-Card at paintsquare.com/ric
