Fire Protection Coatings Evolve to Meet Stricter Safety Demands

Fire safety has never been more critical, yet industries today face a unique challenge: how to enhance fire protection while complying with increasingly strict regulations on toxic chemicals and emissions.

Fire safety regulations are evolving at an unprecedented rate as industries seek safer, more sustainable and high-performance fire protection solutions. Two major forces are driving this transformation. First, regulatory bodies are imposing restrictions on hazardous flame retardants, particularly antimony trioxide (ATO) and halogen-based compounds, due to their environmental and health risks. Second, the focus on smoke suppression is becoming more urgent, as smoke inhalation accounts for over 75% of deaths in fire incidents. In response, recent advancements in intumescent and fire protective coatings are focusing on enhanced char formation, improved smoke suppression and the replacement of harmful synergists.

Among the most effective solutions, intumescent (IFR coatings) and fire-protective coatings stand out due to their ability to expand and form a protective char layer under fire exposure. These coatings serve as a critical barrier, delaying heat transfer and preventing flame spread, ultimately buying time for evacuation and fire containment.

However, achieving the desired performance in these coatings while addressing the need for reduced toxicity, sustainability and enhanced mechanical properties remains a challenge.

The Science Behind Intumescent Coatings

Intumescent coatings are widely used for structural fire protection, providing a reactive barrier that expands into a thick insulating char when exposed to high temperatures. This process significantly delays the penetration of heat and flame spread, allowing more time for evacuation and firefighting efforts.

The effectiveness of these coatings relies on the interaction of three key components: a carbon source that promotes char formation, an acid source such as ammonium polyphosphate (APP) that facilitates the charring process and a blowing agent like melamine that expands the char layer for better insulation. 

While this system has been effective, the increasing need for better integrity, improved barrier properties and lower toxicity has led to the development of new additives and synergists that enhance the performance of intumescent coatings.

Unlike conventional fire retardants, new intumescent coatings do not just resist fire: they actively respond to it. When exposed to extreme heat, they undergo a controlled chemical reaction that causes them to expand, forming a thick, insulating char layer that acts as a shield against flames.

Advancements in Fire Protection Technology

One of the most significant advancements in this field is the replacement of antimony trioxide (ATO). ATO has traditionally been a key component in fire retardant coatings, known for its ability to improve flame resistance. However, due to growing concerns over its environmental impact and potential health risks, regulatory frameworks such as REACH and ECHA are pushing for its phase out.  

In response, newer formulations are utilizing ADINS® additives as an effective alternative. Technologies like this offer comparable or even superior fire resistance while eliminating hazardous substances, improving char stability and reducing toxic byproducts. The shift toward ATO-free coatings aligns with the broader industry trend of transitioning to halogen-free and low-toxicity fire protection solutions, ensuring compliance with increasingly rigorous global regulations.

Smoke is often the most lethal aspect of a fire, particularly in enclosed spaces such as buildings, trains and aircraft, where thick smoke can rapidly obscure visibility and increase inhalation risks. Traditional intumescent coatings, while effective in slowing flame spread, do not always address smoke emissions. However, recent technological advancements have focused on modifying the thermal decomposition process of coatings to minimize the formation of toxic volatiles. By enhancing the gas barrier properties of the char and reducing smoke density, new formulations have demonstrated significant reductions in overall smoke production.

Another crucial area of innovation in fire protection technology is improving the structural integrity of the char layer. A fire-resistant coating is only as effective as its ability to maintain a stable protective barrier under high temperatures. If the char is brittle or prone to cracking, heat penetration accelerates, reducing the coating’s ability to insulate against fire. A new range of ceramization-enhancing additives significantly improves the stability and mechanical strength of the char layer in intumescent coatings. After combustion, they reinforce the structure inside the char, resulting in a highly stable, compact and consistent ceramic-like carbon structure.

Smoke emissions, often the most dangerous aspect of a fire, are also significantly reduced. The ceramification process modifies the decomposition of materials, lowering the release of toxic volatiles and decreasing total smoke production.

To sum up: the latest advancements in char reinforcement leverage new additives to optimize the foaming process, resulting in a denser and more uniform char layer. These additives act as nucleating agents, strengthening the char’s mechanical properties and enhancing its thermal barrier function.

Flame Retardancy Proof Points

Studies have shown that the incorporation of this new technology in intumescent coatings can reduce the total smoke production by up to 60%, helping to improve safety conditions in enclosed environments. Smoke chamber testing has shown up to a 22% decrease in smoke density and a 22% reduction in total smoke production, contributing to safer evacuation conditions in the event of a fire.

Also, studies on this new flame retardant technology have demonstrated up to a 38% reduction in peak heat release rate (pHRR) and a 25% decrease in the maximum average rate of heat emission (MARHE), reinforcing the long-term protection capabilities of intumescent coatings.

These innovations are already making a significant impact across various industries. One of the key benefits of this new technology is its compatibility with a wide range of coatings and resins. Whether in water-based or solvent-based systems, these additives enhance fire protection across various polymeric matrices.

Sectors such as electric vehicles and technical textiles require next-generation fire protection technologies that not only resist fire but also actively enhance material performance. Manufacturers can achieve enhanced char stability, improved thermal insulation in batteries, making coatings safer.

Also in transportation, fire protective coatings are being optimized to meet EN 45545-2 standards, ensuring reduced flame spread and lower smoke emissions in railway materials.

Structural fire protection in the construction industry is benefiting from enhanced intumescent coatings that align with EN 13381 requirements, improving heat insulation and prolonging fire resistance in steel structures.  

Meanwhile, electrical and industrial applications are incorporating low-smoke, zero-halogen coatings for fire-resistant and enclosures, reducing toxicity without compromising performance.

New-generation fire retardant coatings, including technologies like ADINS Flame Retardancy, are leading the shift toward a safer, more environmentally responsible industry. These advanced coatings not only meet the highest fire safety standards but also demonstrate that sustainability and efficacy can go hand in hand. With lower emissions, reduced toxic smoke and full compliance with evolving regulations, such technologies are proving that fire protection no longer has to come at the cost of environmental impact. 

As fire safety regulations continue to evolve, the future of fire protection will rely on intelligent formulations that balance sustainability, safety and performance. The integration of additives, ATO-free formulations, represents a major leap forward in fire safety innovation. The industry is shifting toward solutions that not only resist fire but actively mitigate its dangers, reduce its toxic impact and ensure safer environments for all. With ongoing advancements in material science and regulatory compliance, the next generation of intumescent and fire protective coatings is set to redefine how industries approach fire safety for decades to come.