Effects of intumescent formulation for acrylic-based coating on flame-retardancy of painted red lauan (Parashorea spp.) thin plywood

Abstract

Acrylic emulsion based painted red lauan plywood (Parashorea spp.) is most commonly used for indoor furnishings. This study investigated the enhancement of the fire retardance of painted plywood by interaction among four major components of intumescent formulation: (1) acrylic emulsion resin as binder resin (BR), (2) pentaerythritol as carbonizing substance (CS), (3) melamine as foam producing substance (FPS) and (4) ammonium polyphosphate as dehydrating agent (DA). Effects of changing BR/CS ratios (designated as FRA series) and FPS/DA ratios (designated as FRM series) on flame-retardance of painted plywood were investigated using a cone calorimeter. The intumescent formulation significantly enhanced fire retardancy of painted plywood by exhibiting lower peak release rates and longer times to reach peak release rates, compared with uncoated plywood (UP) panel and plywood panel solely coated with acrylic emulsion resin. Lower BR content in the FRA series and lower FPS content in the FRM series were shown to enhance flame retardancy of painted plywood. The positive correlation between total heat release values under increasing combustion duration and incremental changes of BR and FPS contents in two series further verified the above findings. Consistent with the observed flame retardancy enhancement of painted plywood, lower heats of combustion and weight losses for paints in the FRM series were also identified by oxygen bomb calorimeter measurements and thermogravimetrical analysis. Infrared analysis of the chars indicated the formation of phosphate ester linkages with the lowest BR content in the FRA series and the lowest FPS content in the FRM series showing superior enhancements of flame retardancy for painted red lauan plywood.