Fire protection systems can mean the difference between minor damage and catastrophic loss in industrial facilities.
Two primary passive fireproofing solutions dominate industrial applications: mortar fire protection and intumescent coatings. Keep reading to select the right protection for your specific requirements.
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What Are Passive Fireproofing Solutions?
Passive fire protection systems provide fire resistance without requiring human intervention. These systems work by insulating structural elements and containing fire spread during fire exposure.
Unlike active systems that detect and suppress fires, passive systems prevent fire damage through continuous protection. They create barriers that slow heat transfer and provide time for evacuation and firefighting operations.
Mortar Fire Protection Systems
What Is Mortar Fire Protection?
Mortar fire protection consists of cementitious materials applied as thick coatings to structural elements. These systems use mineral-based mortars that provide insulation through their thermal mass and low thermal conductivity.
The mortar creates a barrier between fire exposure and structural steel/concrete. During fire conditions, the mortar absorbs heat energy while maintaining its protective properties. This prevents rapid temperature rise in protected elements.
Features of Mortar Fire Protection
Thermal Mass Protection: Absorbs heat energy before transferring it to protected structures; delays temperature rise.
Thickness Flexibility: Can be applied in varying thicknesses to achieve different fire resistance ratings; thicker applications offer longer protection periods.
Weather Resistance: Performs reliably in outdoor environments; suitable for exposed structural elements.
Applications of Mortar Fire Protection
Mortar fire protection works effectively in several industrial scenarios:
Steel Structure Protection: Applied to structural steel beams, columns, and trusses to maintain load-bearing capacity during fire exposure. Commonly used in warehouses, manufacturing facilities, commercial buildings, etc.
Concrete Protection: Protects concrete elements from spalling during high-temperature exposure. Essential for tunnels and parking structures.
Equipment Protection: Safeguards mechanical equipment, piping systems, electrical infrastructure, and more.
Hydrocarbon Fire Protection: Specialized formulations protect against intense hydrocarbon fires in petrochemical facilities and refineries.
Intumescent Coatings
What Are Intumescent Coatings?
Intumescent paints/coatings are thin-film systems that expand when exposed to heat, forming an insulating char layer. This expansion can increase coating thickness by 10-50 times the original application thickness.
The char formation process occurs through chemical reactions that absorb heat energy while creating a low-density insulation barrier. This dual action provides effective fire protection.
Know why this fireproofing material for structural steel safeguards your buildings by maintaining steel strength during fires and ensuring longer evacuation times. Head to our other blog now.
Features of Intumescent Coatings
Expansion Mechanism: Heat exposure triggers chemical reactions that cause the coating to expand into a foam-like char structure that absorbs heat energy.
Thin Application: Coating thickness ranges from 1-5mm, making these systems suitable where space constraints limit thicker applications.
Aesthetic Finish: These coatings can provide attractive finishes in colours that blend with architectural requirements.
Rapid Application: Spray or brush application allows quick coverage of complex shapes and large areas with minimal preparation time.
Applications of Intumescent Coatings
Intumescent coatings serve diverse protection requirements:
Architectural Steel: Protects exposed structural steel in commercial buildings, airports, and public facilities where appearance matters alongside fire protection.
Complex Geometries: Ideal for protecting equipment with intricate shapes, piping systems, and cable trays that demand uniform coating application.
Renovation Projects: Thin profile makes these systems suitable for upgrading fire protection in existing structures without many modifications.
Marine Applications: Specialized marine-grade intumescent coatings protect offshore platforms, ships, and coastal facilities from both fire exposure and corrosive marine environments.
Learn in detail how intumescent coatings protect these 5 industrial steel buildings.
Differences Between Mortar and Intumescent Systems
Application Thickness: Mortar systems require thick applications (25-75mm typical) while intumescent coatings work effectively at thin film thickness (1-5mm typical).
Protection Mechanism: Mortars provide protection through thermal mass and low conductivity. Intumescent systems protect through expansion and char formation during fire exposure.
Installation Requirements: Mortar systems often require reinforcement mesh and specialized application equipment. Intumescent coatings apply with conventional spray or brush equipment.
Environmental Suitability: Mortars excel in harsh outdoor environments and chemical exposure. Intumescent coatings work better in controlled indoor environments or with appropriate topcoats for outdoor use.
Maintenance Considerations: Mortar systems require minimal maintenance once properly installed. Intumescent coatings may need periodic inspection and reapplication depending on environmental exposure.
Sunanda Global’s Intumescent Coating Solutions
Sunanda Global offers specialized intumescent coating systems designed for diverse fire protection requirements:
SUNNOFLAME IP: Water-based system that produces minimal odour and low VOCs; ideal for indoor applications where air quality concerns exist.
SUNNOFLAME IP 1709: Epoxy-based system that provides durability during fire protection under harsh conditions; specifically formulated for hydrocarbon fire exposure.
Why Sunanda Global Is Your Trusted Fireproofing Partner
With over 45 years of hands-on experience in providing advanced fireproofing solutions, Sunanda Global ensures your industrial buildings remain protected with intumescent coatings.
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, industrial or commercial, and are designed to meet Indian safety standards while promoting sustainability.
Choose Sunanda Global for passive fire protection that combines scientific innovation and reliable performance. Contact us today for a free consultation.
