Search Results (174)

Halogenated flame retardants have been amongst the most widely used and effective solutions for enhancing fire resistance. However, their use is currently strictly regulated due to serious health and environmental concerns. In this context, phosphorus-based and mineral flame retardants have emerged as promising alternatives. Despite this, their combined use is neither straightforward nor guaranteed to be effective. This study scrutinizes the interactions between these two classes of flame retardants (FR) through a systematic analysis aimed at elucidating the antagonistic pathways that arise from their coexistence. Specifically, this study focuses on two inorganic fillers, mineral huntite and chemically precipitated magnesium hydroxide, both of which produce basic oxides upon thermal decomposition. These fillers were incorporated into a poly(butylene terephthalate) (PBT) matrix to be utilized as advanced-mattress FR coating fabric and were subjected to a series of flammability tests. The pyrolysis products of the prepared polymeric composite compounds were isolated and thoroughly characterized using a combination of analytical techniques. Thermogravimetric analysis (TGA) and differential thermogravimetric analysis (dTGA) were employed to monitor decomposition behavior, while the char residues collected at different pyrolysis stages were examined spectroscopically, using FTIR-ATR and Raman spectroscopy, to identify their structure and the chemical reactions that led to their formation. X-ray diffraction (XRD) experiments were also conducted to complement the spectroscopic findings in the chemical composition of the resulting char residues and to pinpoint the different species that constitute them. The morphological changes of the char’s structure were monitored by scanning electron microscopy with energy dispersive X-ray spectroscopy (SEM-EDS). Finally, the Limited Oxygen Index (LOI) and UL94 (vertical sample mode) methods were used to assess the relative flammability of the samples, revealing a significant drop in flame retardancy when both types of flame retardants are present. This reduction is attributed to the neutralization of acidic phosphorus species by the basic oxides generated during the decomposition of the basic inorganic fillers, as confirmed by the characterization techniques employed. These findings underscore the challenge of combining organophosphorus with popular flame-retardant classes such as mineral or basic metal flame retardants, offering insight into a key difficulty in formulating next-generation halogen-free flame-retardant composite coatings. Full article

This paper explores the impact of applying a powder additive in the form of halloysite and mullite on the thermal protection properties of a composite. The authors used CES R70 epoxy resin with CES H72 hardener, modified by varying the amount of powder additive. The composite samples were exposed to a mixture of combustible gases at a temperature of approximately 1000 °C. The primary parameters analyzed during this study were the temperature on the rear surface of the sample and the ablative mass loss of the tested material. The temperature increase on the rear surface of the sample, which was exposed to the hot stream of flammable gases, was measured for 120 s. Another key parameter considered in the data analysis was the ablative mass loss. The charred layer of the sample played a crucial role in this process, as it helped block oxygen diffusion from the boundary layer of the original material. This charred layer absorbed thermal energy until it reached a temperature at which it either oxidized or was mechanically removed due to the erosive effects of the heating factor. The incorporation of mullite reduced the rear surface temperature from 58.9 °C to 49.2 °C, and for halloysite, it was reduced the rear surface temperature to 49.8 °C. The ablative weight loss dropped from 57% to 18.9% for mullite and to 39.9% for halloysite. The speed of mass ablation was reduced from 77.9 mg/s to 25.2 mg/s (mullite) and 52.4 mg/s (halloysite), while the layer thickness loss decreased from 7.4 mm to 2.8 mm (mullite) and 4.4 mm (halloysite). This research is innovative in its use of halloysite and mullite as functional additives to enhance the ablative resistance of polymer composites under extreme thermal conditions. This novel approach not only contributes to a deeper understanding of composite behavior at high temperatures but also opens up new avenues for the development of advanced thermal protection systems. Potential applications of these materials include aerospace structures, fire-resistant components, and protective coatings in environments exposed to intense heat and flame. Full article

This study investigates the fire dynamics and structural response of steel-framed warehouse racking systems under various fire scenarios, emphasizing the critical importance of fire safety measures in mitigating structural damage. Through advanced computational simulations (Fire Dynamics Simulator) and thermomechanical analysis, this research reveals that fire intensity and progression are highly influenced by the ignition point and the stored material types, with maximum recorded temperatures reaching 720 °C and 970 °C in different scenarios. The results highlight the localization of significant strain and drift ratios in structural elements near the ignition zone, underscoring their vulnerability. This study demonstrates the rapid loss of load-bearing capacity in steel elements at elevated temperatures, leading to severe deformations and increased collapse risks. Key findings emphasize the necessity of strategically positioned sprinkler systems and the integration of passive fire protection measures, such as fire-resistant coatings, to enhance structural resilience. Performance-based fire design approaches, aligning with FEMA-356 criteria, offer realistic frameworks for improving the fire safety of warehouse structures. Full article

Silica fume-based geopolymer composite coatings, an approach to using metallurgical solid waste, exert flame retardancy with ecological, halogen-free, and environmentally friendly advantages, but their fire resistance needs to be improved further. Herein, a silica fume-based geopolymer composite flame-retardant coating was designed by doping boric acid (BA), zinc phytate (ZnPA), and melamine (MEL). The results of a cone calorimeter demonstrated that appropriate ZnPA and BA significantly enhanced its flame retardancy, evidenced by the peak heat release rate (p-HRR) decreasing from 268.78 to 118.72 kW·m⁻², the fire performance index (FPI) increasing from 0.59 to 2.83 s·m²·kW⁻¹, and the flame retardancy index increasing from 1.00 to 8.48, respectively. Meanwhile, the in situ-formed boron phosphate (BPO₄) facilitated the residual resilience of the fire-barrier layer. Furthermore, the pyrolysis kinetics indicated that the three-level chemical reactions governed the pyrolysis of the coatings. BPO₄ made the pyrolysis E_α climb from 94.28 (P5) to 127.08 (B3) kJ·mol⁻¹ with temperatures of 731–940 °C, corresponding to improved thermal stability. Consequently, this study explored the synergistic flame-retardant mechanism of silica fume-based geopolymer coatings doped with ZnPA, BA, and MEL, providing an efficient strategy for the high-value-added recycling utilization of silica fume. Full article

The oil and gas industry is subject to significant fire hazards due to the flammability of hydrocarbons and the extreme conditions of operational facilities. Intumescent coatings (ICs) serve as a crucial passive fire protection strategy, forming an insulating char layer when exposed to heat, thereby reducing heat transfer and delaying structural failure. This review article provides an overview of recent developments in the effectiveness of ICs in mitigating fire risks, enhancing structural resilience, and reducing environmental impacts within the oil and gas industry. The literature surveyed shows that analytical techniques, such as thermogravimetric analysis, scanning electron microscopy, and large-scale fire testing, have been used to evaluate the thermal insulation performances of the coatings. The results indicate significant temperature reductions on protected steel surfaces that extend critical failure times under hydrocarbon fire conditions. Recent advancements in nano-enhanced and bio-derived ICs have also improved thermal stability and mechanical durability. Furthermore, numerical modeling based on heat transfer, mass conservation, and kinetic equations aids in optimizing formulations for real-world applications. Nevertheless, challenges remain in terms of standardizing modeling frameworks and enhancing the environmental sustainability of ICs. This review highlights the progress made and the opportunities for continuous advances and innovation in IC technologies to meet the ever-evolving challenges and complexities in oil and gas industry operations. Consequently, the need to enhance fire protection by utilizing a combination of tools improves predictive modeling and supports regulatory compliance in high-risk industrial environments. Full article

The thermal conductivity of steel is high compared to other materials such as concrete or timber. Therefore, fire protection measures are applied to prolong the duration between the onset of fire exposure and the final loss of load-bearing function of a steel structure. The most common passive fire protection measure is the application of intumescent coating (IC), a thin film that expands at elevated temperatures and forms an insulating char layer of lower thermal conductivity. This paper focuses on structural steel beams with IPE open-section profiles protected by a water-based IC and subjected to static and standard fire loading. ANSYS 16.0 is used to simulate heat transfer, with thermal conductivity function described by standard multivariate linear regression analysis, followed by mechanical analysis considering degradation of material mechanical properties at elevated temperatures. Simulations are conducted for all IPE profile sizes, with varying initial degrees of utilisation, beam lengths, and coating thicknesses. Results indicated fire resistance times ranging from 24 to 53.5 min, demonstrating a relatively good level of fire resistance even with the minimal IC thickness. Furthermore, artificial neural networks were developed to predict the fire resistance time of steel members with IC using varying numbers of hidden neurons and subset ratios. The model achieved a predictability level of 99.9% upon evaluation. Full article

Fire-resistant coatings have emerged as crucial materials for reducing fire hazards in various industries, including construction, textiles, electronics, and aerospace. This review provides a comprehensive account of recent advances in fire-resistant coatings, emphasizing environmentally friendly and high-performance systems. Beginning with a classification of traditional halogenated and non-halogenated flame retardants (FRs), this article progresses to cover nitrogen-, phosphorus-, and hybrid-based systems. The synthesis methods, structure–property relationships, and fire suppression mechanisms are critically discussed. A particular focus is placed on bio-based and waterborne formulations that align with green chemistry principles, such as tannic acid (TA), phytic acid (PA), lignin, and deep eutectic solvents (DESs). Furthermore, the integration of nanomaterials and smart functionalities into fire-resistant coatings has demonstrated promising improvements in thermal stability, char formation, and smoke suppression. Applications in real-world contexts, ranging from wood and textiles to electronics and automotive interiors, highlight the commercial relevance of these developments. This review also addresses current challenges such as long-term durability, environmental impacts, and the standardization of performance testing. Ultimately, this article offers a roadmap for developing safer, sustainable, and multifunctional fire-resistant coatings for future materials engineering. Full article

This research assessed novel, eco-friendly intumescent coatings utilizing cork and recycled glass as sustainable alternatives to synthetic fire retardants, aiming to reduce environmental impact while maintaining robust fire performance. Coatings underwent up to 600 h of UV light exposure for durability assessment, followed by chemo-physical characterization. Fire exposure tests evaluated in-situ char formation and foaming. All functionalized coatings exhibited suitable intumescent behavior, forming protective char layers even after extensive UV aging. Microscopic analysis showed good additive integration, while FTIR spectroscopy revealed UV-induced chemical changes. Fire resistance tests confirmed the superior performance of functionalized coatings over the commercial reference. The AP-IC system demonstrated the best intumescence, achieving significantly lower maximum temperatures (e.g., 167.3 °C for AP-IC-600) and heating rates. Crucially, the sustainable RG-IC and CK-IC batches showed promising intumescent properties, even improving with UV exposure. Notably, the foamed cross-sectional area of the aged RG-IC samples doubled compared to their unaged counterparts, reaching a maximum temperature of 166.9 °C. These findings highlight the potential of eco-friendly hybrid coatings to enhance fire safety, particularly in critical sectors like naval engineering, aligning with circular economy principles and the growing demand for sustainable, high-performance materials. Full article

This study investigated the thermal performance of reduced super intumescent (RSI) coating, focusing on the correlation between porosity evolution and thermal conductivity under elevated temperature conditions. Porosity development was quantified using scanning electron microscopy (SEM) combined with MATLAB-based image analysis, achieving a maximum porosity of 62% after 60 min of exposure. Thermal degradation was characterized using thermogravimetric analysis (TGA), which recorded a mass loss of 35% between 250 °C and 400 °C, capturing the decomposition kinetics and correlating degradation stages with char formation. Fire protection efficiency was evaluated by employing heat flow meter tests (thermal conductivity reduced from 0.15 W/mK to 0.05 W/mK), methane torch experiments (backside temperature increase delayed by up to 50% compared to uncoated steel), and COMSOL-based heat transfer simulations. The results revealed that the RSI coating’s thermal conductivity decreased as its porosity increased, enhancing its insulation effectiveness. Additionally, the formation of a thermally stable char layer at 400 °C significantly reduced heat transfer to the metal substrate by 66%. These findings support the optimization of bio-derived fire-retardant coatings for passive fire protection applications. Full article

With the acceleration of construction industrialization and carbon reduction goals, prefabricated steel structures are widely used for their efficiency and strength. However, steel’s poor fire resistance limits its use. At high temperatures, steel weakens, leading to collapse risks. Common fire protection methods like rock wool, fire-resistant boards, and coatings focus on single materials, leaving composite systems for modular steel columns understudied. This study systematically examines the fire resistance of modular steel columns with composite protective layers through tests and simulations. It finds that rock wool shrinks under heat, reducing its effectiveness by approximately 66.7%, and suggests construction improvements to mitigate this issue. A simplified fire resistance formula is proposed, showing that the total fire resistance of multi-layer systems approximates the sum of each layer’s resistance. These insights offer practical design guidance and fill a key research gap in composite fire protection for modular steel structures. Full article

Foamed geopolymer materials are increasingly studied due to their inherent fire resistance. To date, these materials have primarily been produced by casting into moulds, with foaming occurring during mixing or within the moulds, shortly before setting. For practical applications, however, it is advantageous to apply these materials directly onto surfaces with complex geometries. Although several techniques for geopolymer spraying have been described in the literature, many exhibit limitations that restrict their practical implementation. This study presents a novel spraying technology developed on a dedicated process line, enabling in situ dosing of the foaming agent immediately before application. The system integrates infrared heating to ensure controlled curing of the geopolymer. This paper outlines the design of the process line and its core functionalities while presenting selected results of material tests conducted on the obtained geopolymer coatings. Tests performed on approximately 200 m² of surface confirmed the functionality of the process. The thermal conductivity of the sprayed foams was about 0.07 W/m-K. The inclusion of a phase-change material (PCM) in the geopolymers further enhanced their ability to store and regulate thermal energy. The adhesion strength results, consistently exceeding 1 MPa across various substrates (steel, geopolymer, gypsum board), confirmed the practical suitability of the proposed solution. This was also demonstrated by the homogeneous foamed structure obtained. Full article

To prevent the vertical spread of fire from flammable components in Building-Integrated Photovoltaic (BIPV) modules during building fires, we applied a fire-resistant (FR) coating technology to the surface of BIPV modules, which are commonly used in Zero Energy Buildings (ZEBs). By applying an acrylic FR coating to the BIPV module, we quantitatively evaluated the influence of heat damage before and after the FR coating, the average propagation rate of flames, and the module failure time in a combustion environment. The results demonstrate that the flame-blocking function and fire diffusion prevention effect of the FR coating are excellent in all combustion environments. Particularly, flame damage is minimized under the condition of an FR coating with a thickness of at least 50 μm. The current work suggests fire resistance mechanisms in various combustion environments and provides the applicability of FR coating technology on BIPV modules for fire non-proliferation. Full article

Modern industrial systems and biomass-fired furnaces require surface treatments that can withstand aggressive chemical, thermal, and corrosive environments. This study investigates the corrosion and thermal resistance of plasma-sprayed Al₂O₃-TiO₂ coatings produced using a DC air–hydrogen plasma spray process. Coatings of compositions of Al₂O₃, Al₂O₃-3 wt.% TiO₂, Al₂O₃-13 wt.% TiO₂, and Al₂O₃-40 wt.% TiO₂ were deposited on steel substrates with a Ni/Cr bond layer by plasma spraying. The coatings were characterized by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) to evaluate their morphology, elemental composition, and crystalline phases. Electrochemical tests were performed in a naturally aerated 0.5 mol/L NaCl solution and cyclic thermal–chemical exposure tests (500 °C using 35% KCl) to assess their corrosion kinetics and thermal stability. The results indicate that pure Al₂O₃ and low TiO₂ (3 wt.%) coatings exhibit fine barrier properties, while coatings with a higher TiO₂ content develop additional phases (e.g., Ti₃O₅, Al₂TiO₅) that improve thermal resistance but reduce chemical durability. Full article

Recent research has focused on developing environmentally friendly flame-retardant coatings to improve the fire resistance of wood. In this study, phytic acid–guanazole (PG), a dual-functional compound synthesized through an ionic reaction between phytic acid and guanazole, was added to KH550-modified urea–formaldehyde resin (KUF) as both a curing agent and flame retardant. The $-{\mathrm{PO}}_4^{3-}$ groups from phytic acid act as an acid source to accelerate char formation during combustion, while the −NH₂ groups introduced by guanazole release non-combustible gases to dilute oxygen in the air, synergistically enhancing flame retardancy. Additionally, the hygroscopic $-{\mathrm{PO}}_4^{3-}$ groups absorb free water in the resin, reducing the curing temperature and accelerating coating solidification. The KH550 coupling agent improves compatibility between KUF and PG while introducing silicon, which forms SiO₂ during combustion to strengthen the char layer and further enhance flame resistance. Evaluations showed that PG outperforms conventional tannic acid (TA) in curing efficiency and fire resistance. Comprehensive analyses, including Differential Scanning Calorimetry (DSC), Limiting Oxygen Index (LOI), vertical flame tests, and cone calorimetry, confirmed PG’s dual functionality. Scanning Electron Microscope (SEM) and Raman spectroscopy revealed that PG-modified coatings form denser post-combustion char layers, directly linked to improved fire resistance. As a multifunctional additive, PG eliminates the need for separate curing agents and utilizes bio-based phytic acid, offering cost-effective and sustainable advantages for industrial applications. Full article

Fire has been proven to threaten human lives and buildings significantly. Extensive research is being conducted globally to reduce fire risks, particularly in high-rise buildings that incorporate steel for structural support, timber for decorative elements, and cladding for insulation. Traditional passive fireproofing materials, such as concrete coverings, gypsum boards, and cementitious coatings, often lack aesthetic appeal. Intumescent coatings offer a promising solution to this issue. These coatings require a thin layer on the substrate to protect from fire, and the thin layer expands up to many times its original thickness when exposed to fire, forming an insulating char that acts as a barrier between fire and the substrate. This barrier prevents the steel from reaching critical temperature and helps maintain its integrity during a fire incident. Hence, intumescent coatings are a great choice for passive fire protection of load-bearing steel, wooden structures, timber, and cementitious buildings. Although some research articles discuss intumescent coating types, application methods, fabrication processes, cost-effectiveness, bonding performance, toxicity, and various uses, a comprehensive study encompassing all these topics still needs to be conducted. This review paper explores different types of intumescent coatings, their formulation and manufacturing methods, their application processes, and their use on various substrates. It also covers the key intumescent coating materials and their interactions during fire. Challenges and issues, such as fire protection time, char-forming temperature, and toxicity, are discussed. Full article