Intumescent flame-retardant coating (IFRC) provides a protective barrier to heat and mass transfer for the most efficient utilization of a wide variety of passive fire protection systems at the recent development. This article highlights the fire-resistance, physical, chemical, mechanical, and thermal properties of the IFRC using a Bunsen burner, furnace, Scanning Electron Microscope, freeze-thaw stability test, Instron Micro Tester, and thermogravimetric analysis (TGA) test. The five IFRC formulations were mixed with vermiculite and perlite for the fabrication of fire-resistant timber door prototypes in this research project. Additionally, the best fire-resistance performance of the fire-rated door prototype was selected and compared with a commercial prototype under the fire endurance test. An inventive fire-rated door prototype (P2), with a low density of 636.45 kg/m3
, showed an outstanding fire-resistance rating performance, resulting in temperature reduction by up to 54.9 °C, as compared with that of the commercial prototype. Significantly, a novel fire-rated timber door prototype with the addition of formulating intumescent coating has proven to be efficient in preventing fires and maintaining its integrity by surviving a fire resistance period of 2 h.
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