Intumescent coatings, also called intumescent paints, are one of the easiest and most efficient ways to protect load-bearing elements of buildings and other structures against fire. They can be applied to these structures as an aesthetically pleasing fireproofing coating. Intumescent coatings are typically solvent-based, water-based, or epoxy-based materials that expand when exposed to heat to form a char which protects the structure in case of fire.

The application of intumescent paints in fire protection offers several advantages. Firstly, it does not alter the intrinsic properties of materials, like for instance the mechanical properties of structural steel.

Additionally, it is easily processed and can be used on a wide range of materials such as steel, concrete, timbers, and composite elements.

It is estimated that the global intumescent coatings market will be worth more than $1.2 billion by 2024, with widespread utilization across construction, automotive, and oil & gas applications.

Over the years, structural steel has become increasingly popular in modern architectural design of both commercial as well as industrial buildings. The key factor driving the adoption of intumescent paints is that they expand substantially when exposed to heat. As the material expands it becomes less dense, making it act as an insulator that keeps fire or high temperature away from buildings.

Growing construction activities across all parts of the world due to rapid urbanization promise to offer lucrative opportunities to intumescent coating manufacturers. Leading companies in the industry have made positive efforts to introduce newer, more efficient products into the market.

For instance, in 2018, Nullfire had unveiled a hybrid intumescent coating system called the Nullfire SC902 which was used for more than 2,700 tons of structural steel during the construction at Melbourne Airport’s Southern Precinct. The intumescent coating application was done offsite, and the coated steel was delivered to the construction site.

Citing another instance, Hempel recently unveiled the Hempafire Optima 500 at an event in Bahrain. The company has been aiming to develop a coating works efficiently in warm climatic conditions such as those found in the Middle East and in some parts of Europe.

The Hempafire Optima 500 has been designed specifically to boost the productivity of passive fire protection (PFP) coating applications by minimizing the process time required to apply them and the number of coats required. The coating also complies with environmental regulations as it has less than 1% VOC content in accordance with ISO 11890 requirements.

Hempel claims the Hempafire Optima 500 is a product of the company’s Center of Excellence built to maintain the stability of structural steel in massive infrastructure buildings such as airports, stadiums, and commercial centers. The coating delivers up to three hours of protection against cellulosic fires, being optimized for two hours.

French company Sicomin, a leading manufacturer and supplier of high-performance, bio-based epoxy resins, very recently announced plans to launch a range of new bio-resins at the JEC World 2020 to be held in March. The company will unveil a range of products for automotive, wind energy, and construction applications.

One of the products is the SGi 128, a novel intumescent epoxy-based gel coating developed specifically for fire protection coating applications for critical elements in wind energy and construction applications. The gelcoat is synthesized with 38% of its carbon content derived from non-oil sources.

Also, it is a halogen-free coating that provides excellent fire protection for epoxy laminates and smoke toxicity. The product is available with both slow and fast hardeners, is easy to apply, and forms a much tougher and fireproof part surface compared to traditional intumescent coatings.

Impact of rising drilling and offshore activities
In November last year, PPG, a leading supplier of paints and coatings, developed its next-generation flexible epoxy-based intumescent coating solution, PPG PITT-CHAR NX. The coating is designed to withstand severe hydrocarbon hazards in both onshore and offshore environments within the oil & gas and petrochemical industries.

When exposed to high temperatures, the coating system expands to form an insulating char that considerably minimizes the rate of heat-up of the structure. Also, the insulation maintains the integrity of the steel structure, buying crucial time for equipment to function and personnel to escape.

The product offers faster application, low thickness, and reduced weight while providing robust durability by retaining PPG’s proprietary flexible technology. The coating is comprehensively tested to comply with all major internationally-recognized fire protection standards.

Improved offshore activity globally along with a substantial number of conventional oil development programs are anticipated to propel drilling slightly this year. It is estimated that global drilling activities will increase by 43,879 wells in 2020. Offshore activity is anticipated to continue to jump by 4.7% to 2,411 wells this year. The Middle East and Africa region remain the industry’s top-performing region supported by multi-year development programs.

An accidental fire is a serious threat to offshore oil & gas operations. It can occur without a warning and escalate quickly. The 2006 BP Deepwater Horizon oil spill which killed 11 and injured dozens highlights the importance of efficient fireproofing. The structural elements of oil & gas rigs need to be able to withstand high temperatures to minimize the chances of structural collapse.

Future intumescent coatings market trends will be majorly driven by rising oil & gas exploration and production activities mainly in the Middle East and increasing infrastructure investments in Asia Pacific.