Optimization of Flame-Retardant Additives on Fire Protection Performance and Thermal Properties of Water-Based Intumescent Coating

Abstract

The aim of this research project was to optimize the effect of flame-retardant additives on the fire protection performances and the thermal properties of water-based intumescent fire protective coatings on steel structures. Four intumescent coating formulations with different ratios of flame-retardant additives (Ammonium polyphosphate (APP), Melamine (MEL) and Pentaerythritol (PER)) were formulated and mixed with the flame-retardant fillers and the water-based polymer binder. The coatings were characterized and examined by using the Bunsen burner test, static immersion test, furnace test, adhesion test, freeze-thaw cycle test, scanning electron microscopy (SEM) and Thermogravimetri Analysis (TGA). The results showed that the Coating 1 with the ratio of APP: MEL: PER of 2:1:1 was effective in fire protection performance, with good quality of water resistance, adhesion strength, promoting a better uniform char layer formation and thermal stability. Significantly, the optimized flame-retardant additives have proved to be efficient in the protection of steel structures against fire and weather resistance.