Efficient flame-retardant and smoke-suppression properties of MgAlCO3-LDHs on the intumescent fire retardant coating for steel structures

Abstract

MgAlCO3-layered double hydroxides (MgAlCO3-LDHs) were introduced in a waterborne intumescent fire retardant (IFR) with nano-coating containing ammonium polyphosphate (APP), pentaerythritol (PER), and melamine (MEL). The effects of MgAlCO3-LDHs were evaluated based on thermogravimetry (TG), differential thermal analysis (DTA), Fourier transform infrared spectroscopic analyses (FT-IR), X-ray power spectroscopy (XPS), scanning electron microscopy (SEM), fire performance test, and cone calorimetry. The 1.8 wt% of MgAlCO3-LDHs added to the IFR coating promoted the expansion of the char layer to improve its thermal insulation performance during the fire performance test. The results characterized by TG, DTA, XPS, and FT-IR revealed that MgAlCO3-LDHs enhanced the residual weight, the thermal stability and the oxidation resistance of the IFR coating. There was statistical evidence that the heat-shielding performance was reinforced by adding an appropriate amount of MgAlCO3-LDHs to the IFR coating to form uniform and compact foams in the char layer by using the digital image to process SEM images. The cone calorimetry revealed that a 46% reduction in total smoke production (or total smoke release) and a 25% decrease in the smoke production ratio were achieved in the coating with added MgAlCO3-LDHs compared with that without. It can be concluded that the addition of MgAlCO3-LDHs to IFR coating actively interacts with APP, PER, and MEL, thus improving the fire retardant properties of the coating.