Topcoats versus Durability of an Intumescent Coating

Epoxy-based intumescent coatings are effective solutions for protecting steel against fire. To design a successful product, it is, however, of primary importance to investigate its long-term durability. Some of these coatings do not resist accelerated aging conditions such as contact with salted water. One solution to overcome this drawback consists of applying a specific topcoat. In this work, various topcoats were applied on a model intumescent coating. Topcoats were shown to impact, under heating, the char expansion, char morphology, and char strength. The general trend is that the topcoats, before any aging exposure, improve the fire resistance behavior of the intumescent coatings. Most topcoats, however, do not limit penetration of salted water into the coating, thus affecting the intumescent properties. Only a silane-based topcoat was reported to trap or limit the diffusion of sodium and chlorine ions, thus protecting the underlying intumescent coating.