Innovation in Intumescent Coating Technology

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This Online Learning Seminar is available through a professional courtesy provided by:

Contego International, Inc.P.O. Box 49Rochester, IN 46975Toll-Free: 800-434-6444Email: [email protected]: http://contegointernational.com/

©2015 Contego International, Inc. The material contained in this course was researched, assembled, and produced by ContegoInternational, Inc. and remains its property. The LEED® Rating System was authored by and is the property of the USGBC. Any portion of the Rating System appearing in this course is by permission of the USGBC. Questions or concerns about the content of this course should be directed to the program instructor. This multimedia product is the copyright of AEC Daily.

Innovation in Intumescent Coating Technology

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Innovation in Intumescent Coating Technology

Contego International, Inc. Email: [email protected]. Box 49 Web: http://contegointernational.com/Rochester, IN 46975

The U.S. has the worst fire fatality rate in the industrialized world, and consideration should be given to the use of intumescent acrylic latex paint for its fire-resistance attributes. This course outlines the evolution of intumescent coatings. The program focuses on intumescent acrylic latex paint coatings and the performance and aesthetic advantages they have over traditional coatings. It includes discussions on codes and standards, applicable substrates, adhesion, and application, curing, and cleanup.

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The American Institute of Architects · Course No. AEC810 · This program qualifies for 1.0 LU/HSW Hour.

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Learning Objectives

Learning Objectives:

At the end of this program, participants will be able to:

• explain the purpose of, and technology behind, intumescent coatings

• summarize the performance advantages that intumescent acrylic latex paint coatings have over cementitious and cellulose intumescent coating products

• recall various testing standards related to durability, safety, and performance that must be met to ensure building code compliance, and

• describe the importance of adhesion of intumescent acrylic latex paint coatings as well as the need to follow application and curing guidelines to guarantee product performance.






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Table of Contents

Overview of Intumescent Paint 6

Common Applications 16

Meeting Codes and Standards 28

Adhesion 38

Application, Curing, and Cleanup 44

Case Studies 50

Summary 62

Click on title to view






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Overview of Intumescent Paint






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History of Fire Retardant Paints

In the early 1950s, flame retardants first appeared, offering a new level of protection from fires. While they were not able to arrest fires, they were effective in slowing the development, giving additional time to evacuate and more time to react to a fire. These first generation coatings were expensive, difficult to apply, and foul smelling. Virtually all early flame retardants were formaldehyde-based, extremely toxic, and carcinogenic. These early fire-resistant coatings required special equipment to apply and specially trained contractors to install, and the cost per square foot was painfully high. Other trades had to stay away from the job while they were being applied, creating scheduling nightmares.

The image shows the fire-resistant coating cracking and rust penetrating through the surface.






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Cementitious products, which consist of lightweight cement and cellulosic fiber, much like newspaper, are cheap and quick to apply. These materials are often used on tunnels or girders that are enclosed within walls of a building, since their thick, “papier-mâché” appearance is very unattractive.

Like cementitious products, cellulose coatings go on dirty and thick. An inherent problem with these types of fireproofing materials is that the application instructions indicate not to prime the steel. Unprimed steel is completely vulnerable to rust and typically arrives at the construction site with rust already forming.






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In many of these products, boric salts and other component ingredients are corrosive and promote rust. Once rust has started, it doesn’t stop, and nothing bonds to rust. It’s just a matter of time before the fireproofing delaminates and falls off. Some cellulose-based, cementitious, and mastic coatings are very destructive to steel and can be too heavy for the structural loading of the project.






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What Is an Intumescent Fire Retardant Paint?

Work began in the mid-1980s to perfect a new genre of coatings called intumescent reactants. The term “intumescent reactant” (IR) generally defines a type of coating that expands when exposed to high temperatures or direct flame, forming a “char barrier” several inches thick. This results in an effective and durable barrier that either cuts off the fuel source a fire needs to develop, or creates an insulating blanket to retard heat rise in structural steel.

Until recently, most intumescents met with only limited success because they had obvious deficiencies and limitations. Traditionally, intumescents have been thick, gummy, foul smelling, toxic, carcinogenic, ugly, and expensive. Some products that claimed to be non-toxic and non-carcinogenic still used formaldehyde and other toxic substances. In fact, read the MSDS for almost all intumescent reactants (usually Section 10), and you will see warnings for both acute and chronic damage to the brain and central nervous system. They have required exotic preparations like two-part epoxy primers and couldn’t be top coated, or you had to buy the manufacturer’s specially formulated top coat. They had limited shelf life, and some had to be periodically reapplied, which, of course, is impossible given the nature of the product and the application process. Other products did not bond well to surfaces, and other coatings, like paint, did not bond well to them. The defects in the formula caused them to produce a fragile char barrier that was easily compromised. Once compromised, fire could undermine the rest of the intumescent layer, rendering it useless.

This was the very beginning of intumescent technology, and it served to usher in the next evolution of the technology.






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The Transitional Generation in Fireproofing

A new generation of intumescent reactant coatings appeared 30 to 35 years ago with all the problems of the past, but was even more expensive and hard to apply. All of the other disadvantages were and still are there, but this interim generation was a far better solution than the products that looked like oatmeal and fell off the steel, so typically had to be wrapped in drywall on columns and other sections where the steel would be exposed. Many had (and still have) disturbingly short latencies. If not reapplied (which, as we discussed above, is impossible), they wouldn’t work in a fire. That’s why many have very short warranties. Many of these are still sold popularly in the architectural market. You have to read the fine print in the MSDS and product data to pick them out.






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New Generation of Intumescent Coatings

Significant advances in polymer technology mean new formulations outperform products of the past. Depending on the manufacturer, intumescent acrylic latex paint coatings apply like regular paint; there are no special tools required. Some coatings can be applied using a brush, roller, or standard sprayer. They can smell, feel, and apply like high-quality latex paint. Intumescent coatings have a broad range of applications since the polymer base allows them to bond tightly to many different substrates. They are non-carcinogenic, won’t irritate the skin, and safe for use around children and pets. They have a pleasant scent, with no solvents or VOCs.

New Technology

Old Technology






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New Generation of Intumescent Coatings

For most combustible substrates, two coats (14 to 20 mils dry) meets or exceeds any fire-resistance needs mandated by building code. On structural steel, 40 mils dry film thickness (DFT) can provide the kind of fire resistance that used to require as much as 200 mils of the transitional products that are still sold. In terms of fireproofing, intumescent acrylic latex paints vary in terms of how many coats need to be applied for the same protection. Source a manufacturer whose paint is designed to offer maximum fire protection without having to apply an excessive number of coats, to save both time and money. As the chart below indicates, coating thickness varies greatly by manufacturer. Last but not least, intumescent acrylic latex paint is very economical to use. Architects and specifiers who want to highlight the building’s structure can opt for intumescent acrylic latex paint.

Sample Thickness Required for 2-Hour Application

Brand A Brand B Brand C Brand D

W 10x49(Wide Flange Beams or Columns) 310 mils Not possible 113 mils 77 mils

HSS 8x8x.500(Hollow Square Sections) 334 mils 186 mils 93 mils 42 mils






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How Intumescent Products Work

Intumescent products are made of a series of chemicals suspended in a binder. When the binder is exposed to heat, it begins to soften, opening up the suspended chemicals to the heat. The chemicals react, which releases vapors that create a foam. A carbonization occurs and the foam solidifies into a black insulating material that is often referred to as char.

They protect the substrate.

They expand and form a thick char barrier that protects substrates from heat and fire.






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Why Use Intumescent Paint?

General Fire Facts

1. Fire doubles every 60 seconds.

2. Over 2 million fires are reported to fire departments each year in the USA.

3. New York City alone has more fires each year than Japan.

4. There are over ten billion dollars in property damages in the USA each year from fire.

5. Despite the use of sprinklers and smoke alarms, the USA has the worst fire fatality rate in the industrialized world.

6. Fires kill more Americans annually than floods, hurricanes, tornadoes, and earthquakes combined.

7. In deadly home fires, 14% had working smoke detectors and alarms.

8. Smoke detectors failed to operate in 44% of reported fires.

9. You have no sense of smell when sleeping.

10.Almost 40% of fire victims die in their sleep.






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Common Applications






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Where Have Intumescents Traditionally Been Used?

In spite of their shortcomings, intumescents have played a valuable role in high fire risk situations such as oil refineries,offshore oilrigs, tankers, and large chemical manufacturing facilities. Due to their shortcomings, most previous intumescents had to be applied with a trowel or specialty sprayer and required a highly trained operator. In addition, they had to be applied in a thick layer (150 to 200 mils) to achieve acceptable protection. Today, with dramatic improvements in the state of the art, intumescents are in high demand for virtually any substrate in any design.

A white intumescent acrylic latex paint applied on steel

Intumescent acrylic latex paints have been proven effective on a wide array of substrates such as wood (both dimensional lumber and manufactured woods like OSB, MDF, plywood, etc.), concrete, drywall, structural steel, aluminum, spray polyurethane foam, and more. They should not be applied on Styrofoam®

or EPS since that material is liquid fuel at less than 200 °F, and all intumescents react at about 360 °F.






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Substrate: Wood or Wood By-Products

Regardless of the lumber chosen for a project, be it dimensional lumber, or engineered lumber products such as plywood, oriented strand board (OSB), laminated strand lumber (LSL), particle board, medium-density fiberboard (MDF), or any other type of manufactured wood product, the investment should be protected with a high-quality intumescent acrylic latex paint.






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Substrate: Wood or Wood By-Products

Two coats of intumescent acrylic latex paint on conventional lumber can replace the use of pressure-treated fire-resistant wood (PTFR), meet code requirements, and save on average 25% of the cost of using PTFR. That figure includes the cost of labor to apply it. It’s important to realize that PTFR is highly toxic and carcinogenic. It also requires the use of stainless steel fasteners due to the fact that the chemicals in the PTFR will dissolve other fastener materials. According tofindings by the USDA, the process used in the creation of the PTFR actually breaks down the lignans of the wood; those lignans are essential to the structural integrity of the wood.

Intumescent acrylic latex paint can be top coated without affecting its fire resistance. According to test results from leading independent fire testing laboratories for one manufacturer’s product, top coating improves performance by as much as 32%.






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Substrate: Concrete

Concrete has certain advantages over other building materials because of its inherent fire-resistive properties. However, it is still important to use a protective fire barrier on concrete to negate the effects of heat produced by a fire.

Concrete must be able to withstand loads without collapse. During a fire, the rise in temperature causes a decrease in the strength and amount of elasticity of the concrete and steel reinforcement. Fully developed fires cause expansion of structural components such as rebar.






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Substrate: Concrete

The rise in temperature causes the free water in concrete to change from a liquid to highly pressurized steam. Essentially, the water trapped inside acts like millions of tiny kernels of popcorn that can explode with enormous energy. This change in state causes changes in the rate at which heat is transmitted from the surface into the interior of the concrete wall or concrete column. This can result in “spalling” or fractures in the material, triggering a collapse. In addition, the rate at which the strength decreases depends on the rate of increase in the temperature of the fire and the insulating properties of concrete.

The application of intumescent acrylic latex paint controls the rise in temperature, thus protecting the structure from the rapid shift in temperature, greatly reducing the risk of spalling and possible collapse.






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Drywall/gypsum wallboard (GWB) is an accepted fire barrier; however, it is also a huge fuel source for the first few minutes of exposure to a fire, or even temperatures higher than 451 °F. That’s because the paper fascia on gypsum wallboard, even fire rated GWB, is paper coated with flammable paint. Not only is it an enormous fuel source, it may also be toxic in a fire. Once the paper burns off, the gypsum goes to work protecting the substrate; but initially, the painted paper fascia will flare and can accelerate temperature rise and trigger flashover in adjoining rooms.

Substrate: Drywall

By using a standard GWB and applying a coating of intumescent latex paint, you achieve superior drywall fire protection and approach the parameters of a “Type X” rating. A 10 mil DFT (dry film thickness) coat of intumescent acrylic latex paint adds 55 minutes of burn time to any layer of GWB. This can be enhanced to more than two hours when used as a primer. The coating protects the paper fascia while maintaining a flame spread and smoke production rating of 0×0. To receive the “Type X” designation under ASTM C1396, a gypsum board product must be shown to achieve not less than a one-hour fire-resistance rating for ⅝" board when tested in specified building assemblies/systems in accordance with the requirements of ASTM E 119, Standard Test Methods for Fire Tests of Building Construction and Materials.






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Substrate: Structural Steel

The application for structural steel and architectural metals, such as the skeleton of a building or the steel trusses in a roofing system, is extremely important. Although steel obviously does not burn when exposed to fire, it loses its structural integrity and collapses once the core temperature reaches prescribed limits causing the structure to collapse, as in the World Trade Center or the McCormick Place fire in 1969. Intumescent acrylic latex paint products reflect heat, reducing the risk of structural collapse.

World Trade Center McCormick Place






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Substrate: Structural Steel

Two big factors not normally discussed are the erosion of steel from rust damage and structural loading. Both problems come from continuing reductions in the mass of steel used in a structure because of cost. The W/D ratios of structural members are engineered to the lowest possible because of the skyrocketing cost per ton of steel. The savings can be enormous, but there is no margin for error. Older fire-resistance technology starts destroying the steel the moment it’s applied, and as mentioned earlier, once started, it never stops. A W/D*, Hp/A*, or A/P* ratio that was once acceptable is now too low because of obvious reductions in mass and structural integrity. Also, fire-resistance technology using cement is extremely heavy. If not factored into the original structural engineering, the building is overloaded the day the doors open.

*W = Weight of steel section in pounds*D = Heated perimeter of steel section in inches *A = Cross-sectional area of steel section in inches*P = Heated perimeter of steel section in inches *Hp = Perimeter of steel exposed to fire in inches






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Substrate: Aluminum

Since most aluminum alloys melt in the vicinity of 1,100–1,200 °F and moreover, begin to display significant reduction in tensile and yield strengths at temperatures well below this, protection of structural aluminum in the event of a fire is an important concern. One manufacturer’s independent testing shows better than two hours of protection on .250 aluminum columns with only 50 mils dry film thickness of intumescent paint.

Intumescent acrylic latex paint can be used for anything from protecting aluminum ventilation ducting in mines, to the aviation and aerospace communities where complex challenges like cargo holds of commercial jets, military aircraft, and experimental designs can be problematic to protect with other products.






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Substrate: Polyurethane Insulation

As energy prices skyrocket, so does the demand for insulation and energy-saving techniques and products. Spray polyurethane foam is a fast and economical way to insulate. However, spray polyurethane foam (SPF) is not only combustible, but SPF, when ignited, burns exponentially, producing intense heat and dense, black smoke. Because SPF is a polyisocyanurate, a sizeable component of the dense, black smoke is actually cyanide gas, but none of the off gassing is dangerous and harmful.

Generally, if space is unoccupied, an “ignition barrier” is required by code. If the space is to be occupied, a “thermal barrier” is needed. A thermal barrier is defined in IBC-2603.2-4 and the test runs 15 minutes.

Intumescent acrylic latex paints are available that are easy to apply with the spray equipment already required for the project, are completely non-toxic, and can be top coated with acrylic enamel for special applications that require wash-down, such as coolers, produce facilities, slaughterhouses, and more.






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Where Are Intumescent Paints Used Today?

Intumescent acrylic latex paints are commonly used by the following:

• hotels/resorts

• theme parks

• casinos

• hospitals

• churches

• schools

• universities

• correctional facilities

• major airports

• municipalities

• assisted living centers

• nursing homes

• telephone companies

• fireproofing specialists

• food processing centers

• distribution warehouses

• banks

• restaurants

• leading architects

• general contractors

• paint contractors






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Meeting Codes and Standards






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Product Testing

It is critical that testing be performed to code-based standards and that you source a manufacturer whose testing is performed by independent laboratories that are established, accredited, audited, and certified. Source a manufacturer with ISO 9001 certification.

Depending on the manufacturer, products are tested to numerous standards including: • Underwriters Laboratories (UL)• Underwriters Laboratories of Canada (ULC)• ASTM International• National Fire Protection Association (NFPA)• Uniform Building Code (UBC)• American National Standards Institute (ANSI)

For the international marketplace:• European Committee for Standardization (CEN) • International Organization for Standardization (ISO) • British Standards Society (BSS)






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Product Testing

Types of Tests Performed with Various Substrates

Wood or WoodBy-Products

• UBC 26.2 Test Methods for the Evaluation of Thermal Barriers

• UBC 26.3 Room Fire Test Standard for Interior of Foam Plastic Systems

• ASTM D3359 Standard Methods for Measuring Adhesion by Tape Test

• ASTM E-84.98 Flame Spread and Smoke Production on PMDO (UL-723, ANSI A-2.5, NFPA 255 & UBC 8-1 & 42-1)

• UL 723 Flame Spread and Smoke Production on Douglas Fir - 2 Coats (ASTM E-84, ANSI A-2.5, NFPA 255 & UBC 8-1 & 42-1)

• NFPA 286 Standard Methods of Fire Test for Evaluating Contribution of Wall & Ceiling Interior Finish to Room Fire Growth

• ASTM D4541-09e1 Pull-Off Strength of Coatings Using Portable Adhesion Testers

Concrete

• ASTM E119-08 Standard Methods of Fire Tests of Building Construction & Materials

• BSS 7239-88 Test Method for Toxic Gas Generation by Materials on Combustion


• ASTM D4017 Volatile Organic Compound Content

• ASTM E283-04 Test Method for Determining Rate of Air Leakage






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Product Testing


Drywall

• ASTM E119/UL U-338 Wall Assembly Test on .500 Drywall (UL-263, NFPA-251, UBC-7.1, ANSI-A2.1)



• NFPA 286 Standard Methods of Fire Test for Evaluating Contribution of Wall & Ceiling Interior Finish to Room Fire Growth



Steel

• UL 263/ASTM E119 Full Scale Fire Test for Light Gauge Steel Decking, Concrete, and Beams

• ASTM E119 Standard Methods of Fire Tests of Building Construction & Materials (UL-263, ULC-S101, ANSI A-2.1, NFPA 251 & UBC 7-1)










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Product Testing


Aluminum

• ASTM E119-08 Standard Methods of Fire Tests of Building Construction & Materials• ASTM D4541-09e1 Pull-Off Strength of Coatings Using Portable Adhesion Testers• ASTM D3359 Standard Methods for Measuring Adhesion by Tape Test• BSS 7239-88 Test Method for Toxic Gas Generation by Materials on Combustion• ASTM D4017 Volatile Organic Compound Content

Polyurethane Foam

• EN 13823 (SBI Method) and EN ISO 11925-2• EVS-EN 13501-1:2007 Classification of Reaction to Fire• UBC 26.3 Room Fire Test Standard for Interior of Foam Plastic Systems• ASTM D4541-09e1 Pull-Off Strength of Coatings Using Portable Adhesion Testers• ASTM D3359 Standard Methods for Measuring Adhesion by Tape Test• ASTM E-84.98 Flame Spread and Smoke Production on Polyurethane Foam Insulation (UL-723, ANSI A-2.5, NFPA

255 & UBC 8-1 & 42-1) • ASTM E84-10 Test for Surface Burning Characteristics of Building Materials (UL 723, UBC 8-1, NFPA 255) • BSS 7239-88 Test Method for Toxic Gas Generation by Materials on Combustion• ASTM D4017 Volatile Organic Compound Content






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Sample Testing on Aluminum: No Intumescent

This is an example of a furnace test done on a ⅛" sheet of aluminum with no intumescent protection.

Thermocouples (TC) measured the temperature at timed intervals.

The control sample was destroyed after 18 minutes as it began to melt under the intense heat.

TC 2

TC 3

TC 4TC 6

0

200

400

600

800

1000

1200

1400

1600

1800

15

1015

18

Temperature °F

Time (min)

1 5 10 15 18TC 2 101 180 372 716 900TC 3 178 314 569 854 900TC 4 85 159 304 562 661TC 6 570 623 1230 1550 1651

Bare Aluminum 14x14x1/8






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Sample Testing on Aluminum: With Intumescent

A ⅛" sheet of aluminum protected by three coats of intumescent acrylic latex paint becomes virtually indestructible.

Thermocouple 6 was located on the exposed side of the test sheet rising to a temperature of 1,600+ degrees Fahrenheit.

Thermocouples 2, 3, and 4 were on the back of the sheet indicating a maximum temperature of 350 degrees.

The test was terminated after 2 hours and 15 minutes.

TC 2

TC 4

0

200

400

600

800

1000

1200

1400

1600

1800

1

10 20 30 40 50 60 70 80 90

100

110

120

130

Temperature °F

Time (min)

1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 13TC 2 77 204 283 321 337 352 349 350 343 333 334 327 327 327 332 334 329 329 329 327 333 328 324 330 339 338 340 34TC 3 108 320 329 336 359 358 355 363 366 362 358 354 346 349 361 353 350 353 362 367 372 371 366 372 382 382 382 38TC 4 82 223 308 338 362 374 367 375 354 355 352 347 342 345 366 348 338 338 352 353 363 370 363 367 375 375 377 37TC 6 450 1001 1237 1518 1644 1630 1644 1642 1602 1611 1627 1624 1634 1617 1660 1658 1613 1605 1610 1628 1648 1627 1623 1647 1640 1613 1635 162

Aluminum 14x14x1/8 with 21 mil of Paint






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In-Field Shed Burn Test

Video Placeholder

You will be required to view the video on YouTube. Click here to access and click on the Adobe PDF icon in the taskbar or the “back” button to return to the course.

https://youtu.be/g1nN1AanqKg






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In-Field House Burn Test

You will be required to view the video on YouTube. Click here to access and click on the Adobe PDF icon in the taskbar or the “back” button to return to the course.

https://youtu.be/_M_gGD2g0JI






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LEED® v4

LEED v4 Credits Applicable to Paints and Coatings

Category Credit Maximum Possible Points

Materials & Resources

Building Product Disclosure and Optimization -Environmental Product Declarations

Building Product Disclosure and Optimization -Sourcing of Raw Materials

Building Product Disclosure and Optimization -Material Ingredients

2

2

2

Indoor Environmental Quality Low-Emitting Materials 3

Sustainable Sites Heat Island Reduction 2

Intumescent acrylic latex paint is available that has zero VOCs and zero toxins, which means it may contribute to LEED points earned on a building project in some of the credit categories above.






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Adhesion






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Testing for Adhesion

During a fire, intumescent coatings and technology (like intumescent caulk) can protect steel and other substrates from direct exposure to flames and dangerously high temperatures.

However, a coating’s fire protection is based on its adhesion—or how well it sticks to a substrate—and its cohesion—or how well the coating holds together.

Adhesion is tested in two ways: by tape test or pull-off adhesion test.

• During a tape test (ASTM D3359), cross cuts or ribbon cuts are made in a coated surface. A special tape is used to try to pull off the paint.

• The pull-off adhesion test (ASTM D4541-09e1), which is the industry’s more definitive test, evaluates adhesion by placing a steel plug on the coated surface. A large amount of pressure is applied to pull up the plug and the coating. Technicians then determine if the failure was adhesive or cohesive.

Ideally, what you want to see is an adhesive failure, because that means you’re getting the maximum strength out of the coating, and the failure is not within the coating, but rather at the substrate level.






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Importance of Adhesion

Name one other type of coating where adhesion isn’t critical. Would anyone accept the paint on his or her house falling off or the finish on their automobile disappearing? In this case, it’s not just about an architectural finish; it’s about minimizing property loss and gaining necessary time to save lives.

The images above illustrate what happens when an intumescent is applied in a cold, humid environment on steel that has not been primed. The result is moisture being trapped beneath the coating, which eventually expands causing delamination.






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Protective coatings need to adhere to steel and other substrates, even at extremely high temperatures. When a building catches fire, intumescent coatings heat up and expand 10 to 75 times their original thickness, so 1 millimeter of coating could expand to as much as 40 to 50 millimeters.

Without strong adhesion, the coating flakes off, exposing steel to intense heat. When steel heats up to 1,000 °F/535 °C (the temperature a building fire quickly and easily exceeds), it loses half its strength.

At 1,000 °F/535 °C, a steel beam supporting 200 tons can only support half that weight, putting the structure at risk of collapsing. In a fire, steel softens and deforms, so much so that if heated to 1,200 °F/650 °C, a giant steel beam could easily bend.

Strong adhesion in intumescent acrylic copolymer latex paint allows the coating to stick to the steel, even when heat causes the steel to lose shape. Additionally, the intumescent coating keeps the steel from reaching those dangerous temperatures by insulating the substrate, even at elevated ambient temperatures, such as during a fire. While a fire might be burning at 2,000 °F/1095 °C, the coating keeps the steel at a safe temperature long enough to allow firefighters to intervene and residents to escape.






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Fire-resistant coatings can’t withstand heat indefinitely, but the goal is to protect the steel long enough so the fire burns out, the structure is safely abandoned, or help arrives. Furnace fire tests and control burns show that intumescent acrylic latex paint protects steel extremely well.

Test chamber after a burn test

Preparing beams for glass furnace

Preparing for room burns

Thermal barrier test






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Fortunately, most buildings won’t experience a fire. Still, the same adhesive properties that allow intumescent coatings to protect in a fire also help coated surfaces tolerate other elements that could be destructive to the substrate below. After substrates are coated, they’re often left for 20 years or more, so coatings need to help protect these surfaces and maintain their integrity for many, many years.

During a 20-year period, surfaces can be subjected to a wide range of environmental conditions like dirt, dust, wind, and rain, as well as industrial equipment or vehicle traffic. A strong adhesive coating allows surfaces to withstand these conditions for decades.






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Application, Curing, and Cleanup






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Application

The surface being treated must be completely clean, dry, and free from dirt, debris, or oil residue.

An intumescent coating is latex-based, and while it can be applied over an existing finish, it is necessary to know what the existing finish is. If alkyd, or unknown, an adhesion test is recommended. If the existing finish is in good shape, apply a bonding primer before applying the intumescent acrylic latex paint. The coating will last as long as it adheres to the substrate and is not damaged or penetrated.

A high-quality intumescent acrylic latex paint behaves just like any high-quality latex paint, and no license or permit is required to apply this type of product. Some can be applied with a brush, roller, or mitt, or an airless spray gun.






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Application

In terms of a top coat, any high-quality 100% acrylic latex, oil-based, enamel, or latex finish coat will work. While top coating is optional, it is always a good idea—and absolutely required for exterior applications or interior applications that will be exposed to high levels of humidity, water spray, or chemical vapors like chlorine. To add color or sheen to the surface of intumescent acrylic latex paint, use virtually any alkyd or enamel paint as soon as the intumescent coating is completely dry. As mentioned, depending on the manufacturer, top coating does not reduce intumescent capability and will in fact make the char barrier tougher and more fire resistant.






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Curing

This sample intumescent acrylic latex paint drying chart is based on the humidity (R/H) and temperature, and indicates the estimated hours required for the paint sample to dry before top coating.

• Thin coat (0.3 mm/300 μ/ 12mils wft)

• Medium coat (0.6 mm/600 μ/ 24 mils wft)

• Thick coat (0.89 mm/889 μ/ 35 mils wft)

Curing Chart - Recoating Time Guidelines

10 °C / 50 °F 20 °C / 68 °F 30 °C / 86 °F

R/H Spray Still Air Air Flow Still Air Air Flow Still Air Air Flow

30%*Thin

MediumThick

4.50 hrs6.25 hrs9.00 hrs

2.25 hrs3.75 hrs4.50 hrs

3.75 hrs5.25 hrs6.00 hrs

1.50 hrs3.00 hrs3.75 hrs

2.25 hrs4.50 hrs6.00 hrs

1.50 hrs2.25 hrs3.00 hrs

50%Thin

MediumThick

5.60 hrs9.00 hrs12.0 hrs

3.00 hrs4.50 hrs6.00 hrs

4.50 hrs6.25 hrs9.00 hrs

2.25 hrs3.75 hrs4.50 hrs

3.00 hrs6.00 hrs7.50 hrs

1.50 hrs3.00 hrs3.75 hrs

70%Thin

MediumThick

11.25 hrs15.0 hrs18.0 hrs

6.00 hrs9.00 hrs12.0 hrs

9.00 hrs15.0 hrs18.0 hrs

4.50 hrs6.25 hrs9.00 hrs

6.00 hrs12.0 hrs15.0 hrs

3.00 hrs5.25 hrs6.00 hrs

*R/H 30% or less can cause a surface film to build, trapping moisture inside. In these cases, thinner coats are recommended.






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Curing

Considerations:

• Brushing or rolling doesn’t add to drying time because there’s no way to apply as much with a brush or roller as is applied by spraying. However, because of that, many more coats will be needed.

• Drying times are doubled at 5 °C (41 °F) or at over 75% relative humidity.

• Final drying time before topsealing is a minimum of 16 hours.

• The figures in the chart are based on constant conditions; fluctuations will change the required drying time. If overnight condensation causes wetting, a further full drying period should be allowed.

• Take dry film thickness (DFT) readings as soon as the coating is sufficiently hard to allow a reading to be made without indenting the surface.

• DFT readings may be taken using equipment such as an electronic electromagnetic type or manual gauge.

• Ensure that the DFT of the primer is deducted from the reading of the base coat.

• Do NOT apply a top coat until the readings are in accordance with the specified thicknesses.






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Cleanup

The cleanup of intumescent acrylic latex paint is simple. Just use warm, soapy water as with any latex coating. Since there are no toxins or carcinogens, there are no wastewater disposal issues to consider. As with any latex product, clean out the lines, nozzle, brushes, rollers, and other equipment before the product dries. Fresh overspray can be cleaned up with a damp cloth.

Please remember the exam passwordLATEX. You will be required to enter it in order to proceed with the online examination.






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Case Studies






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Shopping Mall, by Shanghai New Ideal Company, China

When the Shanghai New Ideal Company wanted to protect the exposed steel arches in their 100,000-square-meter commercial center with a fire-resistant coating, they chose an intumescent acrylic latex paint for its thin, smooth, and affordable finish.

With over eleven thousand square meters of steel to protect, architects embraced the non-toxic and VOC-free intumescent paint formulation for its ability to protect both the applicators and visitors to one of China’s premier shopping malls.






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III Fifty One Water Street, St. John’s, Newfoundland

While architecturally designed to carry on the long-standing heritage of Water Street charm, III Fifty One incorporates the best of today’s newest technologies, including being the first to be heated and cooled by seawater. This stunning new development includes an innovative six-story, 168,000-square-foot office tower above prime retail and commercial space, and a 445-car parking area, including 245 public parking spaces.

III Fifty One Water Street has over 30,000 square feet of structural steel beams, columns, and decking protected with a high solids formula of intumescent acrylic latex paint, designed to shield against the most severe cold temperatures and defend against any type of precipitation. It was the ideal solution for the seasons on the St. John’s, NL Pacific Ocean harborfront.






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Saudi Arabia Railway

The SAR (Saudi Arabia Railway) project includes both passenger and cargo railway systems. The passenger service, utilizing advanced modern trains, started in 2014 and has six stations in Riyadh, Majma’a, Qassim, Hail, Al-Jawf, and Al-Qurayyat, all of which have been protected by intumescent acrylic latex paint.

Steel to be painted






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Saudi Arabia Railway

Pictured to the right is a section of the Saudi Rail System being coated with intumescent acrylic latex paint through an in-shop application process, before installation.

It took 1.2 million gallons of paint to complete the entire Saudi system—all the steel, inside/outside.






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South Miami-Dade Cultural Arts Center, Miami, Florida

The South Miami-Dade Cultural Arts Center was stuck with heavy, ugly, expensive mastic fireproofing that was destroying the steel until they were introduced to intumescent acrylic latex paint. It provided a uniquely attractive finish that didn’t take away from the remarkable architectural statement seen here.






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Port of Miami, Miami, Florida

The Port of Miami had issues with the previous fireproofing system used—the coating was rippling and delaminating, and actually served as a fuel source in this condition. Their solution was to coat the structural steel with intumescent acrylic latex paint, protecting the steel and enhancing the aesthetic of the cruise ship terminals.






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British Antarctic Survey, Halley Research Station

The British Antarctic Survey (BAS) is one of the world’s leading environmental research centers and is responsible for the UK’s national scientific activities in Antarctica. Intumescent acrylic latex paint was chosen to protect the Halley Research Station from fire in the world’s most difficult climate.






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Winnipeg Soccer Stadium, Winnipeg, Manitoba

The Winnipeg Soccer Stadium—Investors Group Field, the stunning new stadium in Winnipeg, Manitoba, Canada, which opened in 2013, is located on the University of Manitoba campus next to University Stadium. It is home to the Winnipeg Blue Bombers of the Canadian Football League, University of Manitoba Bisons football team, and the Winnipeg Rifles (CJFL). The stadium is one of the venues for the 2015 FIFA Women’s World Cup, hosted by Canada. The stadium has a capacity of 33,422 (partially covered) and contains a corrugated metal roof, restaurant, 52 suites, walk of fame, and other amenities. Fireproofing the steel with intumescent acrylic latex paint allowed for a thin coat that is paper-smooth—so thin and so smooth that, even after being top coated, there’s no clue the steel has been treated. The application work was performed by Canadian Thermal.






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Malmstrom Air Force Base, Great Falls, Montana

Intumescent acrylic latex paint is a popular choice of the U.S. Government and Department of Defense. Malmstrom Air Force Base in Great Falls, Montana uses intumescent acrylic latex paint to protect living quarters, the recreational facility, and other operational structures against the threat of fire.






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Hilton Garden Inn

In this four-story Hilton Garden Inn project, the builder used conventional lumber instead of pressure-treated fire-resistant lumber which was required by code. Replacing the lumber would’ve been cost-prohibitive, so the solution was to spray a coat of intumescent acrylic latex paint on the existing lumber, and the project passed code.






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Condominium Project

This is an example of a high-density condominium structure with 1,200 units. The general contractor installed ⅝" Type X gypsum board on the ceiling, unaware that current code required 1" Type C gypsum board. A 7.5 ml (15 ml wet) coat of intumescent acrylic latex paint was added after completion to bring the structure up to code.






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Summary






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Summary

Intumescent acrylic latex paint—the newest generation of intumescent coatings—is a water-based coating that can be applied to virtually any type of building material including wood, concrete, drywall, structural steel, aluminum, spray polyurethane foam, and more. The paint has a broad range of applications since the polymer base allows it to bond tightly to many different substrates.

When exposed to high heat or fire, the thin film coating swells or “intumesces,” forming a tough char barrier that stops the fire by blocking access to the fuel it needs to grow. Once the fire has been extinguished, extensive testing by certified laboratories clearly shows the resulting foam layer actually minimizes the damage to the substrate. Often the substrate may still be useable. In many instances, the protective char can be scraped off, revealing that the underlying substrate is still sound, and repair can be achieved at a fraction of the cost.

Both regular and high solids formulations smell, feel, and apply like high-quality latex paint. It is non-carcinogenic, non-dermatic, has zero VOCs, and is completely safe for use around children and pets. For most combustible substrates, depending on the manufacturer, two coats (14 to 20 mils dry) gives as much protection as 150 to 200 mils of older-generation intumescents, and it is much lighter, economical to use, and more aesthetically pleasing.






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Conclusion

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Innovation in Intumescent Coating Technology