Thermal Protection and Combustion Behavior of Intumescent-Coated Cross-Laminated Timber in Encapsulated Sandwich Wall Assemblies Under Medium-Scale Radiant Exposure

Cross-laminated timber (CLT) is increasingly used in multi-story timber construction, but its combustible nature requires reliable fire protection, particularly in layered wall assemblies with concealed cavities. This study compares two medium-scale cross-laminated timber (CLT) sandwich wall assemblies exposed to radiant heat flux of 20 kW/m2 for 90 min: an uncoated reference assembly and an assembly with PROMADUR® intumescent coating applied to the CLT surfaces. Both specimens consisted of a 90 mm three-ply CLT panel encapsulated with 12.5 mm gypsum-fiber boards fixed to a wooden stud frame forming a 40 mm installation cavity. Fire-test observations were supplemented by simultaneous thermal analysis (STA), i.e., thermogravimetry (TG)/differential thermogravimetry (DTG)/differential scanning calorimetry (DSC), of uncoated and coated CLT specimens under oxidative conditions. During the applied medium-scale radiant exposure, the unexposed-face temperatures of both assemblies remained below the insulation temperature-rise limits defined in STN EN 1363-1; however, these limits were used only as a comparative benchmark and the test does not represent a formal fire-resistance classification. The coated assembly showed improved thermal protection during the early and intermediate stages of exposure, delaying a critical thermal event near the wooden stud by approximately 35 min. However, flaming combustion of the stud occurred at about 75 min and led to degradation of the intumescent char within the cavity. In contrast, the uncoated assembly reached higher early CLT surface temperatures but showed no flaming combustion during the test. STA results supported the fire-test interpretation: the coated specimen showed a 37% reduction in peak DTG rate, a higher residual mass at the end of the test, and substantially greater mass loss in the 150–280 °C range, consistent with intumescent activation and volatile release. The results indicate that, under the tested medium-scale exposure, the intumescent coating improved early and intermediate thermal protection of the CLT surface, but did not prevent late-stage cavity flaming involving the wooden stud. Therefore, the behavior of intumescent-coated CLT in partially enclosed cavities with combustible framing should be validated under replicated, standardized and larger-scale fire exposure.