Impact of the intumescent formulation of styrene acrylic-based coatings on the fire performance of thin painted red lauan (Parashorea spp.) plywood

Abstract

Intumescent material with commercial resin, such as styrene acrylic copolymer resin, has been demonstrated to be extremely effective in improving the fire performance of wooden materials used for indoor furnishing. The formulation of the coating is a key to its ability to improve flame retardance. This study investigates the enhancement for painted thin red lauan (Parashorea spp.) plywood. The ability of the material to retard flame arises due to the interactions between the four major components of intumescent formulation: (1) a binder resin (BR), styrene acrylic emulsion resin, (2) a carbonizing substance (CS), pentaerythritol (3) a foam producing substance (FPS), melamine and (4) a dehydrating agent (DA), ammonium polyphosphate. This paper compares the fire performance of the plywood when coated with resin of differing BR/CS ratios (designated as the FRS series) and FPS/DA ratios (designated as the FRD series), by means of a cone calorimeter. These intumescent formulations significantly enhanced the fire retardancy of painted plywood, exhibiting lower peak heat release rates, higher expansion of the intumescent layer and longer time to peak heat release rates (PHRR), when compared to plywood panels coated with sole binder resin. However, worse performance was presented when compared with the data for uncoated plywood panels if the intumescent was produced by equal ratio of the four components. Therefore, the formulation of the intumescent is important. Additionally, lower BR contents in the FRS series and lower FPS contents in the FRD series further enhanced flame retardancy. Advanced investigation by IR and 31P NMR demonstrated that lower BR and FPS content extends the survival duration of the phosphor-carbonaceous structure of chars. The findings in this study enhance the state-of-the-art understanding of the effect of the intumescent.