Feasibility Study on Novel Fire-Resistant Coating Materials

Over the last few decades, wildfires in the United States have caused severe damage and property losses. As more houses are being built in areas prone to wildfire, enhancing the fire resistance of structures and buildings is critical and in great need. This paper presents a preliminary study to explore and develop some innovative surface-bonded fire-resistant coating materials for this purpose. The feasibility of these materials [i.e., high performance cement mortar (HPCM), geopolymer mortar (GPM), and magnesium phosphate cement mortar (MPCM)] was assessed considering the workability, adhesion to structure surface, and fire property. The Taguchi-based mix designs of HPCM, GPM, and MPCM were first evaluated and optimized by using Minitab Response Optimizer. The MATLAB image analysis was used to evaluate the slip resistance of the three optimum mix designs. The cohesiveness, adhesiveness, and fire resistance of the three coating materials were analyzed and compared. The spray area expansion ratio of MPCM was approximately 1.7 times of HPCM and GPM, indicating that HPCM and GPM had better slip resistance than MPCM. The HPCM had the best cohesiveness and adhesiveness with its buildup thickness 0.5 and 1.0 mm higher, and its rebound about 5% and 10% lower than GPM and MPCM, respectively. The fire-resistance test including observation of color change and cracking indicated that MPCM could withstand temperatures as high as 1,000°C, and MPCM had better fire resistance than HPCM and GPM.