Fire protection specifications can determine whether your project meets code requirements or faces costly redesigns. Fireproof mortars and intumescent coatings provide the passive fire protection your structural steel needs during evacuation.
Multiple fireproofing options exist, each serving different purposes. Keep reading to understand which fireproofing solution delivers reliable protection for your project.
Contents
Cementitious Fire Mortars
Cementitious fireproof mortars form the backbone of passive fire protection for many commercial structures. These Portland cement-based compounds contain lightweight aggregates like perlite or vermiculite to create a porous barrier with low thermal conductivity. These are perfect for structural steel columns and beams in high-rise buildings, parking structures, tunnels, and industrial facilities.
Application
The wet spray method provides better adhesion for demanding environments. The dry spray method offers faster coverage where aesthetics are not critical.
Gypsum-based Fire Mortars
Gypsum-based fireproof mortars offer a lightweight and efficient solution for protecting interior structures. Using gypsum as the primary binder, these mortars are ideal for fire-stopping gaps and provide protection for light-weight steel frames. It contains chemically bound water that’s released when heated, providing a cooling effect.
Application
Gypsum-based mortar is mixed with water, and the thickness is determined according to the requirement. They meet the aesthetic needs in environments where the superior durability and moisture resistance of a Portland cement-based system are not required.
Refractory Mortars
Refractory fireproof mortars serve environments with sustained high temperatures. These mortars contain aluminium, silica, or other ceramic materials that maintain structural integrity exceeding 1000°C while resisting thermal shock and chemical attack. Refractory mortars are ideal for furnace linings, kiln construction, and industrial process equipment. Petrochemical plants, steel manufacturing facilities, and power generation stations also rely on these materials.
Application
The application requires careful surface preparation, priming, and proper curing. It is applied through troweling or gunning techniques.
Intumescent Paint
Intumescent paint operates on similar reactive principles but delivers protection through much thinner applications. Heat triggers a chemical reaction that creates expanded cellular char, insulating the substrate while maintaining architectural aesthetics.
Learn more about how mortar fire protection and intumescent coatings differ in their protection mechanisms.
Water-based and Epoxy-based Intumescent Paints
The primary distinction in intumescent paints lies in the binder system, which determines environmental suitability and performance characteristics.
Water-based intumescent coatings The coating foams into a carbonaceous char that insulates the substrate. This can be applied using standard airless spray equipment. These coatings dry quickly and accept topcoats as well, which allows for colour matching to design specifications.
Epoxy-based intumescent coatings can handle harsh environmental conditions and provide dual fire and corrosion protection. The epoxy binder provides superior moisture resistance and chemical protection. Application of this epoxy-based intumescent coating requires careful timing with narrow overcoating windows. Environmental conditions significantly affect cure rates. Proper ventilation is essential during application.
Discover why fireproofing coatings are essential for structural steel in industrial and commercial projects.
How Fireproof Mortars and Intumescent Paints Work Together
Complete fire protection often requires combining different systems for different structural elements within the same project. The key is to match the right system to each element’s specific requirements.
Structural steel framework uses spray-applied cementitious or intumescent coatings for economical protection of large beams, columns, and hidden structural members.
Exposed architectural steel requires intumescent paints to maintain design aesthetics in lobbies, atriums, and open-plan spaces.
Industrial high-heat zones need refractory mortars for continuous thermal protection.
Selection depends on exposure conditions. Interior spaces suit water-based paints. External steelwork needs epoxy-based systems. Extremely high-temperature zones require refractory mortars. Building codes like the National Building Code (NBC) specify ratings based on occupancy type and structural importance.
Sunanda Global’s Fire Protection Solutions
Sunanda Global offers specialized intumescent paint systems designed for diverse fire protection requirements across industrial and commercial projects.
SUNNOFLAME IP – Water-Based Intumescent Paint
This water-based system produces minimal odour and low VOC emissions.
SUNNOFLAME IP suits offices, warehouses, education facilities, and enclosed industrial spaces where air quality matters. The coating applies like regular paint and dries quickly. It provides a smooth architectural finish that accepts topcoats for colour matching to design specifications.
SUNNOFLAME IP 1709 – Epoxy-Based Intumescent Paint
This epoxy-based system provides durability and fire protection under harsh conditions. It is specifically formulated for hydrocarbon fire exposure in aggressive industrial settings
SUNNOFLAME IP 1709 is well-suited for refineries, chemical plants, offshore platforms, and outdoor structures exposed to harsh weather. The epoxy formulation combines fire protection with corrosion resistance in a single system.
SUNNOFLAME MORTAR – Fire Barrier Mortar
SUNNOFLAME MORTAR is a dry white powder consisting of inorganic compounds and perlite, used to reinstate the fire resistance performance of flexible and rigid walls and floor constructions, where they are penetrated by various cables and metallic pipes.
It is suitable for cables, bundled cables, cable racks, cable trays, steel, copper, alupex, plastic pipes, and air ventilation ducts. It has a high degree of mechanical resistance, and the seal is load-bearing without reinforcement.
Why Sunanda Global Is Your Trusted Fireproofing Partner
With over 45 years of experience in Indian industrial construction, Sunanda Global is a trusted fireproofing and waterproofing company and manufacturer of ISO 9001:2015-certified, R&D-driven products. Our solutions cater to diverse sectors, from pharma to petrochemicals, and are designed to meet Indian safety standards while promoting sustainability. Moreover, Sunanda Global provides full support: from technical advice to vetted partners.
Choose Sunanda Global for passive fire protection that combines scientific innovation, safety, and reliable performance.
FAQs
Q1. What are the main types of fireproof mortars and coatings?
The main systems include cementitious, gypsum-based, and refractory mortars, plus water-based and epoxy-based intumescent coatings. Each type suits different fire ratings, aesthetics, and environments
Q2. What is the difference between fireproof mortar and intumescent coating?
Mortars create a thick, insulating layer for concealed steel, while intumescent coatings expand into a char that insulates visible steel with thinner, aesthetic protection
Q3. What are the advantages of using intumescent coatings over traditional cementitious fireproofing?
They provide equal fire resistance with less weight and thickness, faster installation, and a smooth architectural finish. Epoxy coatings also protect against corrosion
Q4. How is intumescent paint applied?
It’s commonly applied using airless spray equipment for even coverage. Surface preparation, correct film thickness, and curing are critical for achieving rated fire performance.
