Search Results (242)

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

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

The global market for flame-retardant materials is expected to grow steadily, from USD 7.0 billion in 2022 to USD 16.6 billion in 2030, driven by increasing demand for environment-friendly fire safety solutions in transportation, construction, and electronics. Polylactic acid (PLA), a biodegradable polymer which possesses excellent mechanical properties, is increasingly being considered for future mobility applications. However, it is characterized by high heat release and toxic smoke during combustion, which are significant drawbacks. In order to address this, the chemical modification of Kraft lignin was achieved through a phenolation and subsequent silylation with tetraethoxysilane, aiming to mitigate the degradation of PLA’s mechanical properties while utilizing its inherent char-forming ability. The modified lignins were combined with ammonium polyphosphate (APP) and melt-mixed with PLA using an injection-mixing molder to prepare test specimens. Analysis by FT-IR, NMR spectroscopy, and SEM-EDS confirmed successful grafting of phenolic and silane functionalities, and thermogravimetric analysis demonstrated enhanced thermal stability of the modified lignins compared to unmodified ones. Vertical burning tests and limiting oxygen index (LOI) measurements showed that the PLA/APP/SPKL composite material achieved a V-0 UL-94 rating and 31.95% LOI, demonstrating the highest level of flame retardancy. This compares to the LOI of neat PLA, 19 to 21%. Despite the enhancement in flame retardancy to the V-0 level, the decline in tensile strength was limited, and the composite retained comparable mechanical strength to PLA-APP composites with V-2 flame retardancy. The findings indicate that the combination of phenolation and silylation of lignin with APP, a flame-retardant material, offers a viable and sustainable methodology for the fabrication of PLA composites that exhibit both flame retardancy and mechanical strength. 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

Phosphorus flame retardants react with cellulose hydroxyl groups via esterification, enhancing the effectiveness of char formation, which is beneficial in terms of the search for bio-sourced flame retardants. The current work assessed the flammability of a new polymer synthesized by Michael 1,4-addition (rP) and modified with developed intumescent flame retardant systems (FRs), in which lignocellulose components, such as sunflower husk (SH) and peanut shells (PS), replaced a part of the synthetic ones. The thermal and thermomechanical properties of the rP, with 20 wt.% each from six FRs, were determined by thermogravimetric analysis (TG), differential scanning calorimetry (DSC) and dynamic mechanical thermal analysis (DMTA). Moreover, the flammability and evolved gas were studied with pyrolysis combustion flow calorimetry (PCFC) and thermogravimetric analysis connected with Fourier transform infrared spectroscopy tests (TGA/FT-IR). The effects were compared to those achieved for unmodified rP and a polymer with a commercially available intumescent flame retardant (IFR). The notable improvement, especially in terms of the heat release rate and heat release capacity, indicates that the system with melamine phosphate (MP) and peanut shells (PS) can be used to decrease the flammability of new polymers. An extensive analysis of the composition and geometry of the ground shells and husk particles preceded the research. Full article

The inherent flammability and hydrophilicity of nylon/cotton (NC) blend fabrics limit their practical applications. Traditional hydrophobic treatments often involve fluorinated compounds or nanomaterials, which raise environmental concerns and exhibit poor durability. To address these issues, this study developed a sustainable multifunctional finishing strategy. Initially, the nylon/cotton blended fabric was pretreated with 3-glycidyloxypropyltrimethoxy silane (GPTMS). An intumescent flame retardant coating based on bio-derived phytic acid (PA) and polyethyleneimine (PEI) was constructed on NC fabrics via a layer-by-layer (LBL) self-assembly process. Subsequently, polydimethylsiloxane (PDMS) was grafted to reduce surface energy, imparting synergistic flame retardancy and superhydrophobicity. The treated fabric (C-3) showed excellent flame retardant and self-extinguishing behavior, with no afterflame or afterglow during vertical burning and a char length of only 35 mm. Thermogravimetric analysis revealed a residual char rate of 43.9%, far exceeding that of untreated fabric (8.6%). After PDMS modification, the fabric reached a water contact angle of 157.8°, indicating superior superhydrophobic and self-cleaning properties. Durability tests showed that the fabric maintained its flame retardancy (no afterflame or afterglow) and superhydrophobicity (WCA > 150°) after 360 cm of abrasion and five laundering cycles. This fluorine-free, nanoparticle-free, and environmentally friendly approach offers a promising route for developing multifunctional NC fabrics for applications in firefighting clothing and self-cleaning textiles. 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

This study systematically examines the effect of the morphology of cerium oxide (CeO₂) on the flame retardancy, thermal stability, and mechanical properties of polypropylene composites with intumescent flame retardant (PP/IFR). Layer-CeO₂ (L-CeO₂) outperforms Particulate-CeO₂ (P-CeO₂) in enhancing the flame retardancy of PP/IFR composites, showing higher limiting oxygen index (LOI) and greater reductions in the total heat release rate (THR) and total smoke production (TSR). The substitution of 1% IFR with 1% L-CeO₂ significantly increased the LOI from 29.4% to 32.6%, while reducing the THR and TSR by 38.9% and 74.3%, respectively. L-CeO₂ incorporation improves thermal stability, increasing the residual char yield to 8.53% at 800 °C under air (vs. 3.87% for PP/IFR). Additionally, L-CeO₂ improved the mechanical properties of the composites, increasing tensile strength and rigidity. The synergistic flame-retardant mechanism is hypothesized to involve CeO₂ catalyzing the formation of a P-O-C crosslinked network in the carbon layer, leading to a denser carbon structure and improved flame-retardant performance in the PP/IFR composites. These findings demonstrate the efficacy of L-CeO₂ as a flame-retardant synergist, providing a foundation for developing fire-safe polymeric materials. Full article

The Wan’an Bridge, the longest wooden lounge bridge in China with a history of more than 900 years, was devastated by a catastrophic fire in 2022. This tragic event underscores the susceptibility of historical wooden structures to fire damage. In this article, the bridge’s intricate structure and the development of the fire incident are introduced in detail. To gain a deeper insight into the patterns of fire propagation across the bridge and assess the reliability of fire simulations in predicting fire spread in historical wooden structures, we utilized the Fire Dynamics Simulator (FDS), with a sophisticated pyrolysis model and thermal response parameters specifically tailored to ancient fir wood. The modeling results reveal that the FDS simulation reflects the actual fire spread process well. Both the investigation and simulation findings indicate that once the flame reaches above the bridge deck, it enters a rapid three-dimensional propagation phase that is exceptionally challenging to control. Furthermore, the modeling results suggest that the application of intumescent fire-retardant coatings can significantly delay fire spread, reduce heat release rates, and suppress smoke production, thereby making them an effective fire prevention measure for historical wooden buildings. 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

This review explores the structural and electrochemical characteristics of carbon materials derived from polybenzoxazines, emphasizing their potential in supercapacitors. A detailed analysis of thermal degradation by-products during carbonization reveals distinct competing mechanisms, underscoring the exceptional thermal stability of benzoxazines. These materials exhibit significant pseudocapacitive behavior and excellent charge retention, making them strong candidates for energy storage applications. The versatility of polybenzoxazine-based carbons enables the formation of diverse morphologies—nanospheres, foams, films, nanofibers, and aerogels—each tailored for specific functionalities. Advanced synthesis techniques allow for precise control over porosity at the nanoscale, optimizing performance for supercapacitors and beyond. Their exceptional thermal stability, electrical conductivity, and tunable porosity extend their utility to gas adsorption, catalysis, and electromagnetic shielding. Additionally, their intumescent properties (unique ability to expand when exposed to high heat) make them promising candidates for flame-retardant coatings. The combination of customizable architecture, superior electrochemical performance, and high thermal resistance highlights their transformative potential in sustainable energy solutions and advanced protective applications. Full article

Louise Nevelson’s Erol Beker Chapel of the Good Shepherd (1977) is a sculptural environment consisting of wooden sculptures painted a monochromatic white color. The paints show signs of degradation including cracking, chipping, peeling, and the formation of blisters and powdery efflorescence. A significant amount of pentaerythritol (PER) detected during a former analysis was concluded to originate from an alkyd paint. We show that the PER originates from the PVAc paint on the sculptures, which we have determined to be an intumescent, fire-retardant (IFR) coating. IFR paints and coatings are functional materials designed specifically to delay the combustion of their substrate. At least one other sculpture by Louise Nevelson is known to have been painted with an IFR coating. Our analyses by Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy with energy dispersive X-ray spectroscopy (SEM-EDX), pyrolysis–gas chromatography/mass spectrometry (Py-GCMS), and cross-section microscopy show the presence and distribution of common IFR additives including PER, dicyandiamide, melamine, inositol, ethylenediamine, and phosphates. These are present throughout the PVAc paint and are enriched in the powdery efflorescence. In addition, the degradation behavior of the paint is typical for IFR coating systems that have been exposed to uncontrolled environmental conditions and especially high humidity events. Full article

Spray-on fireproofing materials (SFRMs) and intumescent paints are commonly used to enhance the fire resistance of steel structures. Despite extensive studies on the performance of SFRMs and intumescent paints, there remains a significant lack of research on the material properties of certified products used in real-world applications, especially according to exposed temperatures. In this study, heating experiments were conducted to investigate the material properties of two widely used certified materials in Korea, focusing on their application thickness and exposure temperature. The experiments set target temperatures ranging from room temperature to 900 °C in increments of 100 °C. Additionally, various material properties, such as changes in shape and the insulation performance of the SFRM and intumescent paint, were observed at each temperature. Notably, the moisture content and discoloration depth of the SFRM displayed a consistent trend under different exposure temperatures, a material property that has not been previously reported. Furthermore, the insulation performance of the two materials differed by approximately 17% to 25% compared to an uncoated specimen exposed to the same temperature. The findings on the properties of SFRMs and intumescent paint relative to the exposure temperature presented in this study can serve as valuable data for selecting materials to improve fire resistance performance across various construction sites in the future. Additionally, they can act as key reference data in the diagnostic evaluation process for assessing the impact of fire on steel structures. Full article

This study explores the development of sustainable fire-resistant composites using a blend of recycled linear low-density polyethylene (rLLDPE) and low-density polyethylene (rLDPE) for construction applications. The incorporation of non-halogenated intumescent flame retardants (IFRs), specifically ammonium polyphosphate (APP) and melamine polyphosphate (MPP), was shown to enhance the flame retardance, thermal stability, and mechanical performance of these recycled polymer blends. IFRs were introduced at 5 wt.% and 10 wt.% concentrations, and their effects were evaluated using limiting oxygen index (LOI) testing and thermogravimetric analysis (TGA). Results showed that 10 wt.% APP and a combination of 5 wt.% APP with 5 wt.% MPP increased LOI values from 18.5% (neat polymer blend) to 21.2% and 22.4%, respectively, demonstrating improved fire resistance. Enhanced char formation, facilitated by IFRs, contributes to superior thermal stability and fire protection. TGA results confirmed higher char yields, with the rLLDPE/rLDPE/MPP5/APP5 composition exhibiting the highest residue (3.00%), indicating a synergistic effect between APP and MPP. Rheological and mechanical analysis showed that APP had more impact on viscoelastic behavior, while the combination of IFRs provided balanced mechanical properties despite a slight reduction in tensile strength. This research highlights the potential of recycled polyethylene composites in promoting circular economy principles by developing sustainable, fire-resistant materials for the construction industry, reducing plastic waste, and enhancing the safety of recycled polymer-based applications. Full article