Enhancements on Flame Resistance by Inorganic Silicate-Based Intumescent Coating Materials

Flame-retardant coatings have drawn much attention in recent years. In this study, an inorganic sodium silicate-based intumescent flame-resistance coating with an excellent flameproof properties is developed by mainly utilizing sodium silicate as the ceramizable binder, via hydrolysis and self-conde...

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Main Authors:	Sin-Nan Chen, Pei-Kai Li, Tar-Hwa Hsieh, Ko-Shan Ho, Yu-Meng Hong
Format:	article
Language:	EN
Published:	MDPI AG 2021
Subjects:	inorganic silicate-based intumescent flame-resistance coating sodium silicate metakaoline expandable graphite geopolymer complex flame-resistance layer Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85
Online Access:	https://doaj.org/article/602f119b0b3445f1a1ed10a01c4e5dd7
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spelling	oai:doaj.org-article:602f119b0b3445f1a1ed10a01c4e5dd72021-11-11T18:09:21ZEnhancements on Flame Resistance by Inorganic Silicate-Based Intumescent Coating Materials10.3390/ma142166281996-1944https://doaj.org/article/602f119b0b3445f1a1ed10a01c4e5dd72021-11-01T00:00:00Zhttps://www.mdpi.com/1996-1944/14/21/6628https://doaj.org/toc/1996-1944Flame-retardant coatings have drawn much attention in recent years. In this study, an inorganic sodium silicate-based intumescent flame-resistance coating with an excellent flameproof properties is developed by mainly utilizing sodium silicate as the ceramizable binder, via hydrolysis and self-condensation reaction. Fly ash, metakaoline, and wollastonite behave as supplement cementing materials. Major formulation encompasses the combination of the ammonium polyphosphate and pentaerythritol as the flame-retardant additives, and aluminum hydroxide or expandable graphite as the intumescence-improving filler agents. Expandable graphite was found to play an important role in the eventual performance of flame-resistance testing. The results showed that solid interaction forces can be formed between metakaoline and sodium silicate, resulting in a similar material to geopolymer with excellent physical properties. After high-temperature flame testing, a densely complex protective layer of carbon-char created on top of the robust silicon dioxide networks offers notable flame resistance. An optimal ratio in this inorganic intumescent coating contains sodium silicate—metakaoline (weight ratio = 9:1)—ammonium polyphosphate and pentaerythritol, aluminum hydroxide (3, 3, 10 wt.%)—expandable graphite (1 wt.%), which can create 4.7 times higher expansion ratio compared with neat sodium silicate matrix. The results of flame testing demonstrate only 387.1 °C and 506.3 °C on the back surface of steel substrate after one and three hours flaming (>1000 °C) on the other surface, respectively, which could meet the requirements according to the level of fire rating.Sin-Nan ChenPei-Kai LiTar-Hwa HsiehKo-Shan HoYu-Meng HongMDPI AGarticleinorganic silicate-based intumescent flame-resistance coatingsodium silicatemetakaolineexpandable graphitegeopolymercomplex flame-resistance layerTechnologyTElectrical engineering. Electronics. Nuclear engineeringTK1-9971Engineering (General). Civil engineering (General)TA1-2040MicroscopyQH201-278.5Descriptive and experimental mechanicsQC120-168.85ENMaterials, Vol 14, Iss 6628, p 6628 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	inorganic silicate-based intumescent flame-resistance coating sodium silicate metakaoline expandable graphite geopolymer complex flame-resistance layer Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85
spellingShingle	inorganic silicate-based intumescent flame-resistance coating sodium silicate metakaoline expandable graphite geopolymer complex flame-resistance layer Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85 Sin-Nan Chen Pei-Kai Li Tar-Hwa Hsieh Ko-Shan Ho Yu-Meng Hong Enhancements on Flame Resistance by Inorganic Silicate-Based Intumescent Coating Materials
description	Flame-retardant coatings have drawn much attention in recent years. In this study, an inorganic sodium silicate-based intumescent flame-resistance coating with an excellent flameproof properties is developed by mainly utilizing sodium silicate as the ceramizable binder, via hydrolysis and self-condensation reaction. Fly ash, metakaoline, and wollastonite behave as supplement cementing materials. Major formulation encompasses the combination of the ammonium polyphosphate and pentaerythritol as the flame-retardant additives, and aluminum hydroxide or expandable graphite as the intumescence-improving filler agents. Expandable graphite was found to play an important role in the eventual performance of flame-resistance testing. The results showed that solid interaction forces can be formed between metakaoline and sodium silicate, resulting in a similar material to geopolymer with excellent physical properties. After high-temperature flame testing, a densely complex protective layer of carbon-char created on top of the robust silicon dioxide networks offers notable flame resistance. An optimal ratio in this inorganic intumescent coating contains sodium silicate—metakaoline (weight ratio = 9:1)—ammonium polyphosphate and pentaerythritol, aluminum hydroxide (3, 3, 10 wt.%)—expandable graphite (1 wt.%), which can create 4.7 times higher expansion ratio compared with neat sodium silicate matrix. The results of flame testing demonstrate only 387.1 °C and 506.3 °C on the back surface of steel substrate after one and three hours flaming (>1000 °C) on the other surface, respectively, which could meet the requirements according to the level of fire rating.
format	article
author	Sin-Nan Chen Pei-Kai Li Tar-Hwa Hsieh Ko-Shan Ho Yu-Meng Hong
author_facet	Sin-Nan Chen Pei-Kai Li Tar-Hwa Hsieh Ko-Shan Ho Yu-Meng Hong
author_sort	Sin-Nan Chen
title	Enhancements on Flame Resistance by Inorganic Silicate-Based Intumescent Coating Materials
title_short	Enhancements on Flame Resistance by Inorganic Silicate-Based Intumescent Coating Materials
title_full	Enhancements on Flame Resistance by Inorganic Silicate-Based Intumescent Coating Materials
title_fullStr	Enhancements on Flame Resistance by Inorganic Silicate-Based Intumescent Coating Materials
title_full_unstemmed	Enhancements on Flame Resistance by Inorganic Silicate-Based Intumescent Coating Materials
title_sort	enhancements on flame resistance by inorganic silicate-based intumescent coating materials
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/602f119b0b3445f1a1ed10a01c4e5dd7
work_keys_str_mv	AT sinnanchen enhancementsonflameresistancebyinorganicsilicatebasedintumescentcoatingmaterials AT peikaili enhancementsonflameresistancebyinorganicsilicatebasedintumescentcoatingmaterials AT tarhwahsieh enhancementsonflameresistancebyinorganicsilicatebasedintumescentcoatingmaterials AT koshanho enhancementsonflameresistancebyinorganicsilicatebasedintumescentcoatingmaterials AT yumenghong enhancementsonflameresistancebyinorganicsilicatebasedintumescentcoatingmaterials
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Enhancements on Flame Resistance by Inorganic Silicate-Based Intumescent Coating Materials

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