The Benefits of Intumescent Coatings for Industrial Buildings

Intumescent coatings are a remarkable fireproofing option that automatically reacts in the event of a fire. There are several benefits to applying intumescent coatings to your business. These include stopping or slowing the spread of fire, meeting insurance and building codes, and most important of all – to protect the safety of your employees.

What are Intumescent Fireproof Coatings?

Intumescent coatings are a specially-formulated type of paint that expands in the presence of fire. Intumescent paint acts as a passive fire protection system and is used in both commercial and industrial buildings. When exposed to flames, the intumescent coating swells up and refuses to ignite, protecting any surfaces or structures beneath it. This barrier stands between the fire and any load-bearing walls or structural beams, giving occupants up to two hours to escape from a burning building before it collapses.

This remarkable coating chemistry is a byproduct of the 911 tragedy. The World Trade Center towers were fireproofed with loose fibrous materials that were old fireproofing technology. The onrushing blast from the impact of the aircraft blew all of the loose materials off the steel superstructure. Intumescent coatings bond the material so this type of tragedy can never happen again.

Intumescent coatings are an important fireproofing option that is low-maintenance and aesthetically-pleasing. In its unburned state, intumescent coatings are practically indistinguishable from a normal topcoat.

How Do Intumescent Coatings Work?

When intumescent coatings are exposed to high temperatures, a chemical reaction occurs that causes the coating to swell up and char. Instead of burning, the intumescent coating will expand, creating an extremely thick protective barrier between the fire and the flammable structure underneath it.

Industrial and Commercial Application

Intumescent coatings are used in industrial settings like factories, warehouses, power plants, offshore platforms, and refineries. In commercial settings they are often used in hospitals, schools, shopping malls, and IT data centers. Intumescent paint is often used to protect travel infrastructure like train stations, subway systems, and airports.

Advantages of Intumescent Coatings

What are the advantages of intumescent coatings? The primary benefit is that intumescent coatings provide passive fire protection. Other benefits include corrosion prevention, reduced maintenance costs, and increased surface durability. Intumescent coatings can also help business owners meet building codes and insurance needs.

Fire Protection

The main advantage of intumescent coatings is fireproofing. When it’s exposed to extreme heat, the intumescent coating will swell up, protecting the surface underneath it. Load-bearing beams and columns are coated with intumescent paint to prevent them from igniting or melting during a fire. The intumescent coating will expand and char, protecting the critical load-bearing structures underneath. This simple form of fire protection can delay or prevent a building from collapsing during a fire.

Corrosion Protection

When moisture and oxygen come in contact with a surface, corrosion can begin. Intumescent coatings consist of multiple layers — the primer, coating, and topcoat — which act as a barrier to corrosive elements. Applying intumescent coatings creates a seal around the surface that keeps out moisture and prevents corrosion.

Durability

Intumescent coatings are very durable and long-lasting. Because it’s anti-corrosive, these coatings can last for several years with minimal maintenance. However, the coatings will slowly deteriorate over time, and need to be reapplied every five to ten years.

Additional Protection for Steel Structures

Intumescent coatings protect steel structures from fire, but they also provide additional protection against everyday corrosion and damage. Steel can be damaged by extreme shifts in temperature and intumescent coatings help mitigate that by insulating the steel against the elements. Coatings also protect steel from impact damage and harsh environments.

Versatility

Intumescent coatings can be applied to virtually all surfaces and materials. Steel, concrete, wood, plaster, and drywall are all suitable. This makes intumescent paint a versatile fireproofing option.

Color Options

Intumescent coatings are generally used for function over form and are typically applied in black, white, or gray colors. After the coating has been applied, you can add an additional topcoat of paint to make it any color you choose.

Cost Effective Over Time

While the upfront cost of fireproof coatings is more expensive than other options like a sprinkler system or fireproof doors, it requires less maintenance and upkeep than other fireproofing options. By saving money on annual upkeep, and preventing fire damage, the initial cost of intumescent coatings is reduced over time.

Meets Building Code and Insurance Needs

Intumescent paint can help your business stay compliant with fire resistance requirements as outlined by your local building codes. Insurance companies may even provide a reduced premium by having passive fireproofing.

Maintenance

Intumescent coatings are low maintenance and require minimal upkeep. In the event that the surface is damaged, additional coating just needs to be applied to the damaged area. Unlike other types of fireproofing that require frequent inspections and upkeep, intumescent coatings require very little  maintenance.

Aesthetics

Unlike other fireproofing options, intumescent coatings are unobtrusive and provide a sleek, smooth finish to surfaces. Other spray-on fireproof coatings that have a popcorn-like appearance, intumescent coatings on the other hand look just like regular paint. This allows it to seamlessly blend in with the building’s architectural design.

Disadvantages of Intumescent Coatings

While intumescent paint brings many advantages, it also has a handful of disadvantages. Cost, environmental considerations, time required to cure, and the fact that these coatings need to be applied by a professional painter are the biggest disadvantages.

Initial Cost

The biggest downside of intumescent coatings is the cost. The up-front cost of intumescent coatings is much more expensive than regular paint. But unlike paint, intumescent coatings protect against fire and are anti-corrosive. Even compared to other fireproofing options, intumescent coatings are still more expensive.

Environmental Considerations

When applying solvent-based intumescent coatings, volatile organic compounds (VOCs) are released into the air. VOCs are bad for the environment and harmful to anyone in the vicinity of solvent-based coatings. Face masks and ventilation are needed for anyone applying solvent-based intumescent coatings.

Time Considerations

For maximum effectiveness, multiple layers of intumescent paint need to be applied. Each of these layers need to completely dry before the next layer can be added. This process is time-consuming and can delay the overall progress of a construction project.

Professional Application

One downside is that intumescent coatings must be applied by a professional. The presence of harsh fumes, chemicals, and making sure it cures correctly means that intumescent coatings can’t be applied by an amateur painter. Because professional application is required, it adds to the total cost of the project which is a downside.

Types of Intumescent Paint

There are three types of intumescent paint: water-based, solvent-based, and epoxy-based. Each of the three different types of intumescent coatings have unique benefits and drawbacks.

Water-Based Intumescent Coating

Water-based intumescent coatings are the most eco-friendly, least expensive, and produce fewer odors than other options. The downside is that water-based coatings are sensitive to humidity and temperature and take much longer to cure. Because they’re not as resistant to the elements, water-based intumescents are generally applied indoors.

Solvent-Based Intumescent Coating

Solvent-based intumescent coatings are more durable than other options, and are often used for outdoor or semi-exposed use. Solvent-based intumescent coatings are resistant to humidity, chemicals, and weathering. Solvent-based coatings cure faster, but give off stronger odors and emit volatile organic compounds (VOCs) during application. Personal protective gear and ventilation are necessary when applying solvent-based coatings.

Epoxy-Based Intumescent Coating

Epoxy-based intumescent coatings have a high chemical resistance and are the most expensive of these three options. Due to its durability it’s often used in extremely harsh environments like chemical plants, bridges, and marine structures. Epoxy-based coatings are often applied to steel beams for fire protection. Epoxy-based is the most expensive type of intumescent paint and is made of two components that need to be combined before application.

Does Your Business Need Fire-Resistant Intumescent Paint?

Are you ready to fireproof your business? Whether you own a shopping mall, factory, chemical plant, or data center, passive fire protection through intumescent coatings is a great idea. Invest in your most valuable asset – your business – by protecting it against disaster with durable, long-lasting intumescent coatings.

Contact Alpine Painting & Restoration

At Alpine Painting & Restoration, our professional commercial painting contractors in Pennsylvania can apply high-quality intumescent paint to help protect your most valuable assets from fire damage. Our reputation for quality painting services is the foundation of our more than three-decades in business. If your Philadelphia-area business is in need of passive fire protection, contact our office to discuss intumescent coatings.

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