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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
Specification & application of Intumescent Coating Systems for the fire protection of structural steel Version 1 page 3
Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
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
Specification & application of Intumescent Coating Systems for the fire protection of structural steel Version 1 page 4
Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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
Specification & application of Intumescent Coating Systems for the fire protection of structural steel Version 1 page 5
Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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.
Specification & application of Intumescent Coating Systems for the fire protection of structural steel Version 1 page 6
Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
Specification & application of Intumescent Coating Systems for the fire protection of structural steel Version 1 page 7
Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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
Specification & application of Intumescent Coating Systems for the fire protection of structural steel Version 1 page 9
Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
Specification & application of Intumescent Coating Systems for the fire protection of structural steel Version 1 page 11
Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
4.2 Intumescent coating system (ICS) components
4.3 Who specifies the required fire resistance?
Specification & application of Intumescent Coating Systems for the fire protection of structural steel Version 1 page 13
Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
4.4 Factors for consideration when specifying an ICS
4.4.1 Design life of intumescent coatings
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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
4.4.3.3 Suitability
4.4.4 Specifying intumescent basecoat thickness requirements
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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
Figure 14 Application of basecoat by spraying Figure 15 Application of basecoat by roller
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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
5.4 Storage of materials
5.5 Mixing of materials
5.6 Scheduling
5.7 Quality control equipment
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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
6.8 Application of additional decorative coat
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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
7.3 Dry film thickness (DFT)
o
o
o
o
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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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
7.4 Dry film thickness (DFT) acceptance criteria
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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
Universal Beam or Column Square or Rectangular Hollow Section
Circular Hollow Section Equal Angle Parallel Flange Channel
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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
7.5 Correction procedure
8.0 Rectification Work
8.1 Damage to existing coatings
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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
9.0 Quality assurance plan
9.1 Inspection
9.2 Records
Example of daily log of environmental conditions
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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
10.0 Conclusion
11.0 Disclaimer
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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
12.0 References
Specification & application of Intumescent Coating Systems for the fire protection of structural steel Version 1 page 35
Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
Partially exposed members
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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
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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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
B2 The use of intumescent coating in conjunction with zinc rich primers
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Specification & application of
Intumescent Coating Systems
for the fire protection of structural steel
Good Practice Guide
Appendix C – Definitions
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