Fire Resistant Coatings Presented by: Jayson L. Helsel, P.E. KTA-Tator, Inc

Fire Resistant CoatingsFire Resistant CoatingsFire Resistant CoatingsFire Resistant Coatings

Presented by:Presented by:

Jayson L. Helsel, P.E.Jayson L. Helsel, P.E.

KTA-Tator, Inc.KTA-Tator, Inc.

Learning ObjectivesLearning ObjectivesLearning ObjectivesLearning Objectives

Comprehension of the Fire Resistant Webinar will Comprehension of the Fire Resistant Webinar will enable the participant to:enable the participant to:

Describe how intumescent coatings protect underlying steel from heat Describe how intumescent coatings protect underlying steel from heat

exposure exposure

Identify the US authority that evaluates and approves intumescent Identify the US authority that evaluates and approves intumescent

coatingscoatings

List two fire rating classification tests that are used to qualify intumescent List two fire rating classification tests that are used to qualify intumescent

coatings for use in building constructioncoatings for use in building construction

Identify two primary resin types that are used to formulate intumescent Identify two primary resin types that are used to formulate intumescent

coatings coatings

Learning Objectives Learning Objectives (cont.)(cont.)

Learning Objectives Learning Objectives (cont.)(cont.)

List characteristics of the resin systems used to formulate intumescent List characteristics of the resin systems used to formulate intumescent

coatingscoatings

Explain how steel size and structure design affect specified thickness and Explain how steel size and structure design affect specified thickness and

number of coats number of coats

Describe the methods used to improve the appearance of the texture of Describe the methods used to improve the appearance of the texture of

intumescent coatingsintumescent coatings

Describe a method to measure the hardness of the applied coating to Describe a method to measure the hardness of the applied coating to

assess cure assess cure

Identify the generic types of primer and finish coats commonly used in Identify the generic types of primer and finish coats commonly used in

conjunction with intumescent coatingsconjunction with intumescent coatings


Sprayed Fire Resistive Materials Sprayed Fire Resistive Materials (SFRM) are broad group of materials (SFRM) are broad group of materials including:including:– Cementitious and gypsum based Cementitious and gypsum based

materialsmaterials– Intumescent coatingsIntumescent coatings

(Note: There is a separate category for “Fire (Note: There is a separate category for “Fire Retardent” coatings, which are not reviewed here)Retardent” coatings, which are not reviewed here)


Intumescent Coatings:Intumescent Coatings:– Are categorized as SFRMsAre categorized as SFRMs– Similar to conventional coatings Similar to conventional coatings – Have unique fire resistant propertiesHave unique fire resistant properties

Intumescent CoatingsIntumescent CoatingsIntumescent CoatingsIntumescent Coatings

How they function: How they function: – Intumescent coatings char and swell Intumescent coatings char and swell

when exposed to fire/heatwhen exposed to fire/heat– The charred layer acts to insulate the The charred layer acts to insulate the

steel from firesteel from fire

Intumescent CoatingsIntumescent CoatingsIntumescent CoatingsIntumescent Coatings

Performance ratingsPerformance ratings– Coatings rated by how long steel is Coatings rated by how long steel is

protected at specified thicknessprotected at specified thickness– Ratings from 1 to 3 hours (at 30 Ratings from 1 to 3 hours (at 30

minute intervalsminute intervals– Specific to shape/size of steel, Specific to shape/size of steel,

e.g. W10 x 49 columne.g. W10 x 49 column

Fire Resistance Fire Resistance ClassificationsClassificationsFire Resistance Fire Resistance ClassificationsClassifications

Underwriters Laboratories (UL) is Underwriters Laboratories (UL) is recognized authority that recognized authority that evaluates and approves evaluates and approves intumescent coatings for a certain intumescent coatings for a certain classification and fire ratingclassification and fire rating

Certifications can be verified online Certifications can be verified online at www.ul.comat www.ul.com


Certifications are “design” specific Certifications are “design” specific by coating manufacturerby coating manufacturer

Numbering system defines an Numbering system defines an alphanumeric design numberalphanumeric design number


BeamsBeams– W, M or S shaped steel sections (AISC)W, M or S shaped steel sections (AISC)– Minimum beam size for fire resistance Minimum beam size for fire resistance

is expressed as W/D ratiois expressed as W/D ratioW = weight of beam per lineal footW = weight of beam per lineal footD = perimeter of protection materialD = perimeter of protection material

– Beams of same configuration with Beams of same configuration with greater W/D ratio may be used in greater W/D ratio may be used in designdesign


ColumnsColumns– Minimum column size and Minimum column size and

configuration specified in X and Y configuration specified in X and Y series designsseries designs

– Same hourly rating applies when Same hourly rating applies when section with equal or greater W/D section with equal or greater W/D ratio is substituted for same ratio is substituted for same configurationconfiguration


Beams and ColumnsBeams and Columns– Required coating thickness increases Required coating thickness increases

as weight of steel decreasesas weight of steel decreasesLighter steel heats up more rapidly and Lighter steel heats up more rapidly and

requires more protectionrequires more protection


Intumescent (and Mastic) CoatingsIntumescent (and Mastic) Coatings– Coating thickness specification in a Coating thickness specification in a

design is minimum average thickness design is minimum average thickness measured in accordance with Technical measured in accordance with Technical Manual 12-BManual 12-BAverage thickness should not exceed Average thickness should not exceed

maximum thickness published (if listed) in maximum thickness published (if listed) in individual designs or byindividual designs or by

No individual measurement <80% of No individual measurement <80% of specified design thicknessspecified design thickness


Technical Manual 12-BTechnical Manual 12-B– Published by Association of the Wall and Published by Association of the Wall and

Ceiling Industries (AWCI International)Ceiling Industries (AWCI International)– Individual measurement = average of 3 Individual measurement = average of 3

gauge readings (similar to SSPC-PA 2)gauge readings (similar to SSPC-PA 2)– Testing frequency one bay per floor or Testing frequency one bay per floor or

one test per 10,000 square feet (further one test per 10,000 square feet (further defines required shapes)defines required shapes)


Technical Manual 12-BTechnical Manual 12-B– ScopeScope– General InformationGeneral Information– Substrate ConditionsSubstrate Conditions– Site ConditionsSite Conditions– Inspection ProceduresInspection Procedures– Method of TestsMethod of Tests– Conditions of Finished ApplicationConditions of Finished Application– PatchingPatching


ANSI/UL 263ANSI/UL 263– Used for resistance to cellulosic fire Used for resistance to cellulosic fire

(e.g. combustion of wood or building (e.g. combustion of wood or building materials)materials)

– Slower rise in temperatureSlower rise in temperature1000 F at 5 min.; 1550 F at 30 min.; 1700 1000 F at 5 min.; 1550 F at 30 min.; 1700

F at 60 min.; 1925 F at 180 min.; 2000 F F at 60 min.; 1925 F at 180 min.; 2000 F at 240 min.at 240 min.

– Interior and exterior exposuresInterior and exterior exposures


ANSI/UL 263 Classified CoatingsANSI/UL 263 Classified Coatings– Typical use for structural steel in Typical use for structural steel in

commercial structurescommercial structures


ANSI/UL 1709ANSI/UL 1709– Used for resistance to a hydrocarbon Used for resistance to a hydrocarbon

firefire– Rapid rise in temperatureRapid rise in temperature

2000 F at 5 minutes 2000 F at 5 minutes

– Interior and exterior exposuresInterior and exterior exposuresEnvironmental tests include, accelerated Environmental tests include, accelerated

aging, high humidity, salt spray, thermal aging, high humidity, salt spray, thermal cycling for exterior exposurecycling for exterior exposure


ANSI/UL 1709 Classified CoatingsANSI/UL 1709 Classified Coatings– Typical use for steel structures at Typical use for steel structures at

petrochemcial facilities, e.g.petrochemcial facilities, e.g.Chemical plantChemical plantRefineriesRefineriesOffshore oil platformsOffshore oil platforms

Other ApprovalsOther ApprovalsOther ApprovalsOther Approvals

Intumescent coatings may also Intumescent coatings may also need approval by city building need approval by city building codescodes

Coating manufacturers should Coating manufacturers should provide approvals as applicableprovide approvals as applicable

Generic Coating TypesGeneric Coating TypesGeneric Coating TypesGeneric Coating Types

Intumescent coatings are generally Intumescent coatings are generally the following generic resin types:the following generic resin types:– Acrylic/vinylAcrylic/vinyl– EpoxyEpoxy

Intumescents are also generally Intumescents are also generally categorized as “thin-film” or categorized as “thin-film” or “thick-film” coatings“thick-film” coatings


Acrylic/vinylAcrylic/vinylThin-film coatingThin-film coatingSolvent or water-basedSolvent or water-basedSingle component Single component Typically rated under UL 263Typically rated under UL 263


Acrylic/vinylAcrylic/vinylApplied in several coatsApplied in several coatsTime-frame for a complete application Time-frame for a complete application

may span several daysmay span several daysAdditional time may be needed before Additional time may be needed before

application of any required exterior finish application of any required exterior finish coat.coat.


EpoxyEpoxyThick-film coatingThick-film coatingApplied by plural component spray Applied by plural component spray

equipment in one or two coatsequipment in one or two coatsRapid cureRapid cureTypically rated under UL 1709 Typically rated under UL 1709


EpoxyEpoxyMay require mesh reinforcement (e.g. May require mesh reinforcement (e.g.

metal, fiberglass, carbon)metal, fiberglass, carbon)Typically requires the use of applicators Typically requires the use of applicators

licensed or approved by the coating licensed or approved by the coating manufacturermanufacturer

Generic Coating Generic Coating ComparisonComparison

Generic Coating Generic Coating ComparisonComparison

Coating Type Required Thickness

(mils)

Number of Coats

Recoat Time

(between coats) @50ºF

Time to Finish Coat

@50ºF

Solvent-based acrylic 130 5 24 hours 25 days

Solvent-based vinyl 375 4 4 hours 20+ days

Water-based acrylic 180 6 8 hours 10+ days

Epoxy 180 1 n/a 24 hours

Epoxy w/mesh 340 1-2 n/a 48 hours

Testing for Coating CureTesting for Coating CureTesting for Coating CureTesting for Coating Cure

Intumescents may require testing Intumescents may require testing for proper curefor proper cure

Typical test is Durometer Hardness Typical test is Durometer Hardness (Shore D)(Shore D)– Resistance of coating film to Resistance of coating film to

indentation by Durometer instrumentindentation by Durometer instrument– ASTM D2240, “Standard Test Method ASTM D2240, “Standard Test Method

for Rubber Property-Durometer for Rubber Property-Durometer Hardness”Hardness”

Testing for Coating CureTesting for Coating CureTesting for Coating CureTesting for Coating Cure

Coating AppearanceCoating AppearanceCoating AppearanceCoating Appearance

Intumescents generally have a Intumescents generally have a rough or orange peel appearancerough or orange peel appearance

Methods to improve include:Methods to improve include:Back rolling following spray applicationBack rolling following spray applicationSanding (not recommended)Sanding (not recommended)Finish coat application (may be required)Finish coat application (may be required)

Coating SystemsCoating SystemsCoating SystemsCoating Systems

Intumescent design approvals Intumescent design approvals typically include a primer and/or typically include a primer and/or finish coatfinish coat– When included in design primer/finish When included in design primer/finish

must be applied to meet fire ratingmust be applied to meet fire rating Primer/finish must be endorsed by Primer/finish must be endorsed by

intumescent coating manufacturerintumescent coating manufacturer– Preference always for same Preference always for same

manufacturermanufacturer

Use of PrimersUse of PrimersUse of PrimersUse of Primers

Intumescent coating manufacturer Intumescent coating manufacturer may have approved list of primersmay have approved list of primers– Types include alkyd, acrylic, epoxy Types include alkyd, acrylic, epoxy

and zinc-richand zinc-rich– Application thickness importantApplication thickness important

PrimersPrimersPrimersPrimers

Function of primerFunction of primer– Provides adhesion to substrate Provides adhesion to substrate – Provides suitable surface for Provides suitable surface for

intumescentintumescent– Provides additional barrier protectionProvides additional barrier protection

Can also provide inhibitive or sacrificial Can also provide inhibitive or sacrificial protectionprotection

Use of Finish CoatUse of Finish CoatUse of Finish CoatUse of Finish Coat

May be required in design approval May be required in design approval for exterior exposurefor exterior exposure

Intumescent coating manufacturer Intumescent coating manufacturer must endorse finish materialmust endorse finish material– Types include 100% acrylic and Types include 100% acrylic and

aliphatic urethane coatingsaliphatic urethane coatings May affect/improve appearanceMay affect/improve appearance

Finish CoatsFinish CoatsFinish CoatsFinish Coats

Function of topcoatFunction of topcoat– Color and glossColor and gloss– Abrasion resistanceAbrasion resistance– Chemical resistanceChemical resistance– WashabilityWashability– Resistance to the environmentResistance to the environment


AcrylicsAcrylics– AdvantagesAdvantages

Single componentSingle componentEase of applicationEase of applicationColor & gloss retentionColor & gloss retentionFlexibilityFlexibilityLow VOC content for waterbasedLow VOC content for waterbased


AcrylicsAcrylics– LimitationsLimitations

Limited alkali and solvent resistanceLimited alkali and solvent resistanceModerate abrasion resistanceModerate abrasion resistanceApplication temperature >50ºF for Application temperature >50ºF for

waterbasedwaterbased


UrethanesUrethanes– AdvantagesAdvantages

Color & gloss retention (aliphatic)Color & gloss retention (aliphatic)AdhesionAdhesionAcid, alkali resistantAcid, alkali resistantChemical resistantChemical resistant Impact/abrasion resistantImpact/abrasion resistant


UrethanesUrethanes– LimitationsLimitations

Multi-componentMulti-componentShort recoat intervalsShort recoat intervalsLimited pot lifeLimited pot lifeMoisture sensitive during cureMoisture sensitive during cureDifficult to recoatDifficult to recoat

Summary of Key PointsSummary of Key PointsSummary of Key PointsSummary of Key Points

When specifying intumescents When specifying intumescents consider:consider:– Required UL approvalRequired UL approval– City building code approvalCity building code approval– Include required primer and finish coatsInclude required primer and finish coats– Applicator certification if needed (e.g. Applicator certification if needed (e.g.

plural component materials)plural component materials)– Include test sections to evaluate Include test sections to evaluate

appearanceappearance

Fire Resistive CoatingsFire Resistive CoatingsFire Resistive CoatingsFire Resistive Coatings

Questions?Questions?

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Fire Resistant Coatings Presented by: Jayson L. Helsel, P.E. KTA-Tator, Inc