Good Practice Guide - FPA Australia B - The use of Intumescent Coatings in Conjunction with Old Paint Coatings .....37 Appendix C – Definitions .....39. Specification & application

Good Practice Guide

Specification & application of Intumescent Coating Systems for the fire protection of structural steel Version 1 page 2

Specification & application of

Intumescent Coating Systems

for the fire protection of structural steel

Good Practice Guide

Acknowledgements





Good Practice Guide

Table of Contents 1.0 Scope ............................................................................................................................................... 5

2.0 Definitions ......................................................................................................................................... 5

3.0 Intumescent coating systems ............................................................................................................ 5

3.1 The use of ICS’s and requirement for fire protection ............................................................... 5

3.2 Components of an ICS ............................................................................................................ 8

3.3 Types of intumescent coating .................................................................................................. 9

4.0 Specifying an intumescent coating system ...................................................................................... 11

4.1 Life of an intumescent coating system ................................................................................... 11

4.2 Intumescent coating system (ICS) components ..................................................................... 12

4.3 Who specifies the required fire resistance? ........................................................................... 12

4.4 Factors for consideration when specifying an ICS ................................................................. 13

5.0 Preparation for application .............................................................................................................. 19

5.1 Allocation of tasks ................................................................................................................. 19

5.2 Factors affecting the choice of application contractor ............................................................ 19

5.3 Material supply ...................................................................................................................... 19

5.4 Storage of materials .............................................................................................................. 20

5.5 Mixing of materials ................................................................................................................ 20

5.6 Scheduling ............................................................................................................................ 20

5.7 Quality control equipment ...................................................................................................... 20

5.8 Documentation ...................................................................................................................... 21

5.9 Health and safety .................................................................................................................. 21

5.10 Environmental conditions ................................................................................................... 21

6.0 Application ...................................................................................................................................... 22

6.1 Marking of steel for identification and traceability ................................................................... 22

6.2 Steel surface preparation ...................................................................................................... 22

6.3 Masking and overspray ......................................................................................................... 23

6.4 Primer application .................................................................................................................. 23

6.5 Condition of substrate for basecoat application ..................................................................... 24

6.6 Intumescent basecoat application.......................................................................................... 25

6.7 Application of sealer coat ...................................................................................................... 25

6.8 Application of additional decorative coat ................................................................................ 26





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7.0 Thickness control of basecoat ......................................................................................................... 27

7.1 Basecoat thickness ............................................................................................................... 27

7.2 Wet film thickness (WFT) ...................................................................................................... 27

7.3 Dry film thickness (DFT) ........................................................................................................ 28

7.4 Dry film thickness (DFT) acceptance criteria ......................................................................... 29

7.5 Correction procedure ............................................................................................................. 31

8.0 Rectification Work ........................................................................................................................... 31

8.1 Damage to existing coatings.................................................................................................. 31

9.0 Quality assurance plan .................................................................................................................... 32

9.1 Inspection .............................................................................................................................. 32

9.2 Records ................................................................................................................................. 32

10.0 Conclusion ...................................................................................................................................... 33

11.0 Disclaimer ....................................................................................................................................... 33

12.0 References ..................................................................................................................................... 34

Appendix A – Fire resistance testing ........................................................................................................... 35

Appendix B - The use of Intumescent Coatings in Conjunction with Old Paint Coatings ............................. 37

Appendix C – Definitions ............................................................................................................................ 39





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1.0 Scope

2.0 Definitions

3.0 Intumescent coating systems

3.1 The use of ICS’s and requirement for fire protection

Figure 1 Sample of structural steel with an intumescent coating system applied.





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Figure 2 Cementitious coating on steel beams Figure 3 Vermiculite coating on steels beams and slab

Figure 4 Board product applied to steel beams and columns Figure 5 ICS applied to steel beams





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3.2 Components of an ICS

Figure 6 Steel beam with intumescent coating system (ICS) including primer, basecoat and sealer

Figure 7 Steel beam with ICS in cross-section





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Figure 8 Intusmecent coating system exposed to radiant heat

3.3 Types of intumescent coating

3.3.1 Thin film intumescent coatings (single component)

3.3.2 Thick film intumescent coatings (two component epoxy)





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4.0 Specifying an intumescent coating system

4.1 Life of an intumescent coating system

Figure 9 Life of an intumescent coating system





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4.2 Intumescent coating system (ICS) components

4.3 Who specifies the required fire resistance?





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4.4 Factors for consideration when specifying an ICS

4.4.1 Design life of intumescent coatings





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Figure 10 ICS failure - bubbling

Figure 11 ICS success – perfect finish

Figure 12 ICS failure – incompatible primer

4.4.2 Testing – fire resistance level

Figure 13 Example of intumescent column (short section) test





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4.4.3 Classification of environment

4.4.3.1 Environments

4.4.3.2 Environments and environmental factors requiring special attention





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4.4.3.3 Suitability

4.4.4 Specifying intumescent basecoat thickness requirements





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4.4.5 Specification and compatibility of basecoat and primer

4.4.6 Specification and compatibility of sealer coat

4.4.7 Standard of cosmetic finish





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Figure 14 Application of basecoat by spraying Figure 15 Application of basecoat by roller





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5.0 Preparation for application

5.1 Allocation of tasks

5.2 Factors affecting the choice of application contractor

5.3 Material supply





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5.4 Storage of materials

5.5 Mixing of materials

5.6 Scheduling

5.7 Quality control equipment





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Figure 16 Wet film thickness gauge – micron scale

Figure 17 Dew point gauge

Figure 18 Dry film thickness gauge

5.8 Documentation

5.9 Health and safety

5.10 Environmental conditions





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6.0 Application

6.1 Marking of steel for identification and traceability

6.2 Steel surface preparation

Figure 19 Steel surface pre-blast

Figure 20 Steel surface after blasting





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6.3 Masking and overspray

6.4 Primer application

Figure 21 Example of masking to avoid overspray onto other surfaces

Figure 22 Steel beam with primer





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6.5 Condition of substrate for basecoat application

6.5.1 Unprimed steel substrate

6.5.2 Primed steel substrate

Figure 23 Application of anti-corrosive primer





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6.6 Intumescent basecoat application

6.7 Application of sealer coat

Figure 24 Steel beam with basecoat

Figure 25 Steel beam with sealer





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6.8 Application of additional decorative coat





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7.0 Thickness control of basecoat

7.1 Basecoat thickness

7.2 Wet film thickness (WFT)

Figure 26 Wet film thickness gauge – micron scale Figure 27 Measuring wet film thickness of intumescent coating





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7.3 Dry film thickness (DFT)

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Figure 29 Beam with parts labelled

Figure 30 Hollow sections (circular, rounded square)

Figure 28 Measuring dry film thickness of intumescent coating





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7.4 Dry film thickness (DFT) acceptance criteria





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Universal Beam or Column Square or Rectangular Hollow Section

Circular Hollow Section Equal Angle Parallel Flange Channel





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7.5 Correction procedure

8.0 Rectification Work

8.1 Damage to existing coatings





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9.0 Quality assurance plan

9.1 Inspection

9.2 Records

Example of daily log of environmental conditions





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10.0 Conclusion

11.0 Disclaimer





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12.0 References

http://www.fpaa.com.au/





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Appendix A – Fire resistance testing

Section factor method (Hp/A)

Example of low and high Hp/A

Calculation of section factor (Hp/A)





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Partially exposed members





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Appendix B - The use of Intumescent Coatings in

Conjunction with Old Paint Coatings

B1 Existing paint layers

B1.1 Removing existing paint layers

B1.2 Applying an ICS over existing paint layers





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B2 The use of intumescent coating in conjunction with zinc rich primers





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Appendix C – Definitions





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Good Practice Guide - FPA Australia B - The use of Intumescent Coatings in Conjunction with Old Paint Coatings .....37 Appendix C – Definitions .....39. Specification & application