An Overview of Fireproofing Methods for Industrial and Commercial Buildings

Fireproofing industrial and commercial buildings is critical to saving lives and minimizing damage associated with fire. In this article, we will delve into the diverse range of fireproofing methods you can use in your facility.
The Importance of Fireproofing a Facility
Unrestrained fires can cause catastrophic damage. In addition to significant property loss, thick smoke, toxic gasses and incredible heat can lead to serious burns, respiratory injury, and fatalities to occupants, visitors, and animals. All this can happen in a matter of minutes; fire needs less than 30 minutes to become uncontrollable.
Time is of the essence when there’s a fire, and more time is what fireproofing provides. When a fire ignites, fire protection systems will notify occupants and reduce the fire’s spread. As a result, building occupants get the widest possible window for a safe evacuation. It can also help minimize costly damage to the facility.
Aside from protecting lives, assets, and buildings, fireproofing is also important for legal purposes. Federal and state requirements dictate minimum compliance standards, and your facility may face fines and other legal penalties if you do not comply.
Passive Versus Active Fireproofing: Definition and Differences
There are various fireproofing methods, but they all fall into either passive or active categories. Active and passive fire protection systems work in concert to protect the building’s occupants and minimize damage associated with a fire. However, they do so in different ways.
Passive fire protection (PFP) uses a set of flame-retardant methods and materials to mitigate temperature impacts on structural materials and component. These systems don’t require human intervention; they automatically work once they come in contact with fire. The composition of the material may extinguish a small fire, reduce flame spread and smoke development, or create a protective barrier between the high temperatures and the building components. Individually and combined, these benefits allow occupants more time to escape and provide firefighters with enough time to put out the flame.
In contrast, active fire protection (AFP) systems must be activated to function. Examples of these are sprinkler systems, fire extinguishers, and smoke alarms. Some of these products are designed to detect smoke, heat, or flames and alert building occupants. Others are made to suppress fires. Products that help clean smoke and aid in evacuation are also categorized as active fire protection systems.
Ideally, facilities use both active and passive fire protection systems to ensure maximum protection. AFP can help alert occupants and put out fires, while PHP slows down the spread of fire from one area to another. Together, AFP and PFP can prevent loss of life, catastrophic injuries, and expensive damage.
Types of Fireproofing Methods
Common and reliable passive fireproofing options include SFRMs, IFRMs, and fire-resistant boards and panels. So, what are these methods of fireproofing?
Spray-Applied Fire-Resistant Materials (SFRMs)
Using spray-applied fire-resistant materials is one of the most common fireproofing methods for commercial and industrial buildings in the United States. Typical SFRMs are composed predominantly of cement or mineral fiber mixed with other materials like vermiculite, perlite, or quartz. These materials are directly sprayed or troweled to beams, columns, and other rigid structural elements.
Upon application, SFRMs encapsulate or coat the steel components. In case of fire, this cementitious coating will delay the rate at which destructive heat reaches and damages the underlying material. Steel tends to weaken, and concrete will spall when exposed to high temperatures, putting occupants and the building at risk. Although SFRMs won’t prevent fire, delaying the rate at which destructive heat reaches and damages the underlying structural support can make a huge difference in saving lives and assets.
Aside from fire protection, SFRMs can also provide thermal insulation and acoustic treatment. These properties, alongside their low cost, make it no surprise that SFRMs have been the go-to fireproofing method for many years. But this option also has a downside: these products may deteriorate when exposed to high moisture and humidity, or general everyday impact damage, rendering them ineffective.
Intumescent Fire-Resistant Materials (IFRMs)
Intumescent fire-resistant materials (IFRMs), known as intumescent coatings, are more advanced passive fire protection for commercial and industrial facilities. These are applied directly to structural elements. When exposed to high heat levels, the relatively thin coating char expands up to 100 times its original thickness depending on the formulation, binder type, and other factors. The coating becomes a barrier between the underlying substrate and the flame.
Unlike the bulky cementitious coating, intumescent coatings are thin and lightweight. They are easier to apply and offer aesthetic versatility. They also require less maintenance over time compared to other fireproofing materials. These characteristics make intumescent coating a common fireproofing choice for walls, ceilings, and other exposed structural elements.
On the downside, intumescent fireproofing can get more expensive as the fire rating increases. You must apply thicker film-intensive coatings in areas with heightened fire risks, such as petrochemical facilities.
Fire-Resistant Boards and Panels
Another way to protect a facility from fire is by using fire-rated boards and panels. You’ll find many variations of these fire-resistant construction materials on the market. Their characteristics, such as melting temperatures and strength-to-weight ratio, vary from one product to another.
Tips for Choosing a Fireproofing Method
With several ways to protect your facility from fire, you might wonder which method and materials best suit your facility’s needs. Below are some tips to help you choose a fireproofing method to comply with applicable federal, state and municipal Codes and give your facility maximum fire protection and your occupants peace of mind.
Learn About Relevant Fire Codes
There are many regulatory entities that establish and oversee fire-related rules and regulations. If you don’t know where to look, start with the International Fire Code (IFC) and the Occupational Safety and Health Administration (OSHA). Their fire-related rules apply to most industrial and commercial construction. Use these rules as your guide in choosing a fireproofing method to keep you compliant with the law.
Learn More About Your Options
This article only covered the basics of several fireproofing options. There is a lot more to learn about them. For instance, intumescent coatings can be solvent-based, water-based, or epoxy-based. They differ in drying times, application, and many other factors. Although a fireproofing expert might walk you through the options and help you choose which would work best in your facility, learning about all the methods is still wise.
Maintain Your Fire Protection System
Even the most durable fire protection system can deteriorate or malfunction over time. Minor breaches in a building’s fireproofing can put your people at risk and result in costly damage. Facility managers must ensure that fireproofing maintenance is a part of their planning and oversight. Fireproof patching services are a critical component of this ongoing maintenance.
Finally, choose your fireproofing contractor carefully. People’s lives and your building are at stake, so it’s better not to take any chances. Thoroughly evaluate the contractor’s experience, work quality, and licenses. It may take a bit of legwork, but the effort and time spent selecting the right contractor will be all worth it.
Fireproof Your Property Today
If you’re looking for fireproofing experts in New England, consider Kaloutas. We offer fireproofing services to facilities in various industries, including but not limited to mixed use commercial, manufacturing, pharmaceuticals, and controlled lab environments. You can count on our experienced and well-trained team to protect your facility so you can focus on your business. We have been fireproofing industrial and commercial spaces for over 30 years.
Our team can do it all, from flooring to painting, cleaning, and inspections. We promise minimal interference to your operations while working on your project. Feel free to contact us to learn more about our fireproofing solutions or get an estimate today.