A smarter fire-resistant coating for safer steel structures

Fire safety remains a critical consideration across multiple sectors, including construction and energy storage. Structural steel must maintain integrity under high temperatures, while lithium-ion batteries require protection against failures such as thermal runaway. A recent study examines a biomass-based intumescent coating designed to address both applications within a single material system. According to the reported findings, the coating also demonstrates smoke suppression, mechanical durability, and water-repellent properties.

In fire-resistance testing, a 1.5 mm coating applied to steel was exposed to a butane torch at temperatures exceeding 1100 °C for 20 minutes. Under these conditions, the temperature on the unexposed side remained below 150 °C. Cone calorimeter tests further indicated a significant reduction in fire intensity, with peak heat release rate reduced by approximately 90% and total heat release by more than 87% compared to conventional coatings.

The material was also evaluated for lithium-ion battery applications. Test results showed that it reduced heat transfer between cells, maintaining the backside temperature below 88.2 °C and slowing the rate of temperature increase. These effects contribute to delaying the propagation of thermal runaway under the tested conditions.

The coating’s performance is attributed to its rapid response under high-temperature exposure. It forms an expanded char layer that acts as a thermal barrier, limiting heat transfer to the underlying substrate. The study highlights the potential of biomass-based, multifunctional intumescent coatings as a fire protection solution for both structural and energy storage applications.