Company profile: International Paint

Following the NIST (National Institute of Standards and Technology) report into the collapse of the World Trade Centre, New York, the application of intumescent Passive Fire Protection (PFP) has become a major issue. Traditionally, intumescent PFP has been applied onsite, but recent product developments now allow offsite application instead, with a surprising number of benefits.

Current thin film cellulosic PFP coating compositions are traditionally based on solvent or water based acrylic resin chemistry and thicknesses will generally be less than 6mm (for up to two hour protection). The formulations are primarily designed for internal use only due to the limitation of the polymer chemistry. These products expand by up to 50 times their original thickness when reacting to a cellulosic fire (wood, paper) and the resultant insulating char, which protects the steel, is relatively soft.

Traditional offshore PFP compositions, on the other hand, due to the aggressive nature of the environment, are based on epoxy resin chemistry. With a high level of turbulence present in hydrocarbon fire scenarios (oil, gas), these products are formulated to expand by only 5-10 times their original thickness, resulting in a char that is very hard and robust. The typical thicknesses of epoxy intumescents range from 3-25mm, giving up to 3 hours fire protection performance.

The New Demand

In general, acrylic intumescents are only suitable for up to ISO 12944 C3 environments (building interiors, urban and industrial atmospheres). Epoxy intumescents are suitable up to ISO 12944 C5, covering the harshest offshore environments. Importantly, epoxy technology is inherently more durable than acrylic technology. There is a growing demand for onshore assets, particularly iconic structures, to be protected with PFP products which offer protection against a wider range of potential fire scenarios (cellulosic and hydrocarbon) and which are more practical in terms of resistance to mechanical damage.

One of NIST’s recommendations (www.nist.gov) in their report into the collapse of the World Trade Centre was “pre-treatment of structural steel with some type of mill applied (offsite) fire protection to minimise the uncertainties associated with field (onsite) application and in-use damage”. What this means is that PFP should ideally be:

• applied offsite to minimise the problems created by application of PFP onsite
• durable enough to lessen damage during transit and erection of steel onsite

Offsite: The Benefits

Applying the correct PFP offsite has the following advantages:

• Pre-protected steel
  The steel arrives at the construction site already fire protected and ready for erection. Should a fire occur during construction, the PFP is already there to protect the asset’s structural integrity.
• Improved quality control procedures
  In shop/offsite, PFP is applied under controlled conditions, with auditable QC procedures helping to ensure that the correct thickness is achieved, usually by skilled applicators. This means PFP can have a better overall appearance than is possible through
  application onsite.
• Reduced cost
  The contractor is free to utilise the services of those companies who are operating in the most cost
  effective locations rather than in locations dictated by the position of the construction site. Application of PFP offsite, in a fabrication hall or yard, frequently leads to increased efficiency due increased availability of steel to coat at ‘ground level’, eliminating probable on-site access restrictions. As there are no large scale access issues, less equipment and scaffolding is needed in the construction area. Nor is it necessary to seal off areas during application or to mask sensitive equipment, both time consuming and costly operations. There is no need for temporary heat and shelters onsite to apply the
  PFP and the work of other trades such as mechanical, electrical and plumbing can start sooner, potentially shortening the entire schedule for the job.
• Improved productivity
  Epoxy PFP can be applied at up to five times the thickness of traditional acrylic materials in one coat. Coupled with rapid cure (<24 hours), this means vastly improved productivity with resultant cost savings.
• Reduced impact on Health, Safety and the Enviornment (HSE)
  The elimination of PFP coating operations onsite reduces the number of chemicals used in the
  construction area and the associated risks. It also contributes to a reduction in access issues, in terms
  of HSE, and simplifies the general co-ordination of onsite activity.

To avoid damaging the coating during the transit and erection of offsite applied products, asset owners should specify an epoxy based PFP. Epoxy PFP technology is intrinsically more durable than an acrylic thin film coating and not susceptible to water intake and premature failure when exposed to
exterior environments. It is also resistant to most handling damage associated with construction, minimizing the need for touch up and repair.

So, when choosing PFP for any structure, it makes sense to ensure that the design process acknowledges the potential problems associated with onsite application. Applying PFP offsite
can help to manage risk, increase efficiency and control costs.

INTERNATIONAL PROTECTIVE COATINGS:
EPOXY FIRE PROTECTION FOR INFRASTRUCTURE
Epoxy fire protection has offered the offshore oil and gas market a combination of superior fire and corrosion protection for more than 30 years. Building on this heritage, Chartek® and, more recently Interchar® 212 epoxy fire protection, are making significant contributions to the safety of structures worldwide.

NEW YORK TIMES TOWER
The New York Times Tower uses epoxy fire protection from International Protective Coatings.

• Fast and efficient installation characteristics
• Tough and durable, suitable for exterior exposure
• Protection against a range of fire scenarios
• UL 263 and UL 1709 listed
• Blast resistant
• Allows freedom of expression to utilise exposed steelwork