Influence of rheological additives on char formation and fire resistance of intumescent coatings

Styrene-butyl acrylate copolymer based fire retardant coatings were prepared using intumescent flame-retardant additives and mineral clay type rheological additives. Three different widely used nanoclays, organic-modified montmorillonite, palygorskite and sepiolite were applied in order to determine their effect on the flame retardancy. Significant differences were found when their heat-shielding activities were evaluated. It was observed that the addition of different clay particles in amount of 0.25 w% changes the char formation process; the height, the morphology, the structure and also the mechanical resistance of the protecting shield. The different geometry and composition of the additives induced different changes in fire performance. In case of palygorskite the catalytic effect of Fe accelerated mainly the thermal decomposition, therefore the fire resistance decreased. The plate-like montmorillonite reduced the extent of the intumescent char, whereas also improved the mechanical and sustained heat resistance of the fire protecting shield. The fibrous sepiolite of low Fe content assisted the development of efficient protecting shield, which exhibited optimal cell structure, suitable thickness, and thus ensured better heat-insulating performance. Consequently, fire retardant effect of sepiolite was found to be better than the other studied clay types.