Buildings 12 01014 v2
Buildings 12 01014 v2
Buildings 12 01014 v2
Article
Research on Thermal Response Behavior of the Intumescent
Coating at High Temperature: An Experimental and
Numerical Study
Lingyun Zhang 1,2 , Yupeng Hu 2, * and Minghai Li 2, *
Abstract: Intumescent coating is able to provide effective fire protection with both practicality and
aesthetics. In this study, expansion performance and thermal physical property experiments are
firstly carried out to obtain the basic parameters at different temperatures. Then, the thermal response
model of the concrete-filled steel tubular (CFST) structure under the protection of intumescent coating
in a fire is established. Finally, based on the experimental data and thermal response model, the
effects of initial thickness, expansion rate, intra-pore emissivity and reaction heat on the structure
temperature are discussed in detail. The results of this study can provide guidance on intumescent
coating formulation design, as well as fire protection design.
improved the intumescent coating’s thermal insulation performance. For instance, the use
of magnesium hydroxide, titanium, zirconium, fire-resistant fibers and nanomaterials were
able to improve the physical and chemical performance at high temperatures [18–25].
The other type of study focused on the thermal response behavior of intumescent
coatings at high temperatures, including pyrolysis, expansion and heat-transfer mecha-
nisms. This type of study provided theoretical guidance for the design and formulation of
intumescent coatings. In the early years, semi-empirical models were developed to describe
the expansion process [26–30]. Blasi and Colomba [31,32] established a mathematical model
to characterize the pyrolysis behavior of the intumescent coating; the model described the
expansion process with some empirical parameters. Some researchers [33–35] established
comprehensive models by considering a combination of the pyrolysis, expansion and
heat-transfer process. Li et al. [36,37] adopted the constant equivalent thermal resistance to
indicate the thermal insulation performance of the intumescent coating. Cirpici et al. [38]
used the bubble growth model to describe the expansion behavior of the intumescent
coating. Zhang et al. [39] studied the couple thermal transfer mechanisms of the porous
char layer, including thermal conduction, convection and radiation.
In this paper, expansion performance and thermal physical property experiments at
high temperatures are carried out to obtain the thickness, thermal conductivity and density
of intumescent coating. Then, a numerical model is established to describe the thermal
response of CFST structures under the protection of intumescent coatings in a fire. Based
on the experimental data and numerical model, this study examines the thermal response
characteristics of the structure. The effect of initial thickness, expansion rate, intra-pore
emissivity and reaction heat are discussed in detail. This results of this study can be applied
to provide guidance on fire protection design.
2. Experiments
2.1. High-Temperature Expansion Performance Experiment
A high-temperature expansion performance experiment of a typical intumescent coat-
ing was carried out to obtain the variation in thickness with temperature. The intumescent
coating used in the experiment was produced by Wuli Coating Co. The substrate was a
surface-treated Q235 steel plate with a size of 120 mm × 120 mm × 3 mm. The initial
thickness of the intumescent coating was 3 (±0.1) mm. The specimen was placed on the
experimental table for dry maintenance. The instrument used for the experiment was the
SX2-10-13A high-temperature electric furnace produced by Chongqing Xinbang Electric
Furnace Company. The electric furnace was composed of two parts: the furnace body
and the temperature-control system, as shown in Figure 1. The maximum range of the
furnace is 1573 K, and a variety of temperature-rise rates can be set to meet the required
test conditions. The main processes were as follows.
(a) The specimen is placed on the refractory brick and surrounded by a certain amount
of sponge to prevent heat dissipation, as shown in Figure 2.
(b) The temperature of the furnace is set according to the working conditions and main-
tained for 1800 s to ensure full expansion at this temperature.
(c) After cooling, the expanded specimen is taken out and the thickness is measured by
vernier caliper.
The expansion thickness and the expansion rate, which is defined as the ratio of the
expansion thickness to the initial thickness, are shown in Table 1. In order to display the
variation trend with the change in temperature more clearly, the data in the table are plotted
as curves, as shown in Figure 3. It can be seen that in the initial stage (293 K to 573 K), the
expansion thickness and rate remained unchanged with the increase in temperature; this is
because the components of the intumescent coating have not yet decomposed. When the
temperature reached 573 K, the expansion thickness and rate increased with the increase in
temperature, which indicates that the decomposition reaction of the foaming agent and
other components started to take place. Then, the expansion thickness and rate continued
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Buildings 2022, 12, x FOR PEER REVIEW 3 of 2
to increase and reached the maximum value at a certain temperature. Finally, the expansion
Buildings 2022, 12, x FOR PEER REVIEW 3 of 20
thickness and rate started to decrease; this is due to the intumescent coating’s oxidation at
high temperatures.
Figure1.
Figure
Figure 1.1. Electric
Electric
Electric
furnace.
furnace.
furnace.
The expansion thickness and the expansion rate, which is defined as the ratio of the
Figure2. 2.
Figure Specimen
Specimen in the
in the furnace.
furnace.
expansion thickness to the initial thickness, are shown in Table 1. In order to display the
variation trend with the change in temperature more clearly, the data in the table are plot-
The expansion thickness and the expansion rate, which is defined as the ratio of th
ted as curves, as shown in Figure 3. It can be seen that in the initial stage (293 K to 573 K),
expansion
the expansion thickness
thicknesstoand
therate
initial thickness,
remained are shown
unchanged in Table
with the 1. in
increase In temperature;
order to display th
variation trend with the change in temperature more clearly, the data
this is because the components of the intumescent coating have not yet decomposed. in the table are plo
ted as curves, as shown in Figure 3. It can be seen that in the initial stage (293 K to 573 K
continued to increase and reached the maximum value at a certain temperature. Finally,
the expansion thickness and rate started to decrease; this is due to the intumescent coat-
ing’s oxidation at high temperatures.
Table 1. Thickness and expansion rate (d3-373 K indicates the initial thickness is 3 mm and the
Buildings 2022, 12, 1014 experiment temperature is 373 K). 4 of 18
Figure 4.
Figure 4.C-Therm
C-Thermconductivity meter.
conductivity meter.
According to the results of the high-temperature expansion performance experiment,
the state of the intumescent coating at different temperatures varied greatly, as shown in
Figure 5. Therefore, the experiment of thermal conductivity was divided into a low-tem-
perature stage and a high-temperature stage. In the low-temperature stage (273 K-573 K),
the intumescent coating was in a dense block state, and we tested the thermal conductivity
Buildings 2022, 12, 1014 5 of 18
Figure 4. C-Therm conductivity meter.
According
According to tothe
theresults of of
results thethe
high-temperature
high-temperature expansion performance
expansion performanceexperiment,
experi-
the state of the intumescent coating at different temperatures varied greatly,
ment, the state of the intumescent coating at different temperatures varied greatly, as shown asin
Figure
shown 5.inTherefore, the experiment
Figure 5. Therefore, of thermal of
the experiment conductivity was dividedwas
thermal conductivity intodivided
a low-tem-
into
perature stage and astage
a low-temperature high-temperature stage. In the stage.
and a high-temperature low-temperature stage (273 K-573
In the low-temperature K),
stage
the
(273intumescent
K–573 K), the coating was in a dense
intumescent coatingblock
wasstate,
in a and we block
dense testedstate,
the thermal
and we conductivity
tested the
directly. However, in the
thermal conductivity high-temperature
directly. However, instage (673 K-1073 K), thestage
the high-temperature intumescent coating
(673 K–1073 K),
reached the expansion temperature and was in a porous carbon layer
the intumescent coating reached the expansion temperature and was in a porous carbon state. We first
pressed the We
layer state. porous carbon layer
first pressed into powder,
the porous then tested
carbon layer the powder
into powder, coating’s
then tested the thermal
powder
conductivity.
coating’s thermalThe conductivity.
specimens areThe shown in Figure
specimens are6.shown in Figure 6.
(a) (b)
Figure 6. SpecimenFigure
for the thermal for
6. Specimen conductivity experiment.
the thermal conductivity (a) Block
experiment. (a) state; (b) powder
Block state; state.
(b) powder state.
Figure 7 displays the thermal conductivities of the intumescent coating before expan-
Figure 7 displays the thermal
sion under conductivities
different temperatures. ofbethe
It can intumescent
seen coating
that the thermal beforeincreased
conductivity expan-
sion under different
withtemperatures. It can beThe
the increasing temperature. seen that for
equation thethe
thermal conductivity
thermal conductivity and increased
the temper-
ature was obtained by linear fitting, as Equation (1). The thermal
with the increasing temperature. The equation for the thermal conductivity and the conductivity at different
tem-
temperatures (273–573 K) can be calculated by the following equation.
perature was obtained by linear fitting, as Equation (1). The thermal conductivity at dif-
ferent temperatures (273–573 K) can be calculated by the− following
λs = 0.00049T 0.0405 equation. (1)
λs =λ0.000103 T ++0.0475
s = 0.000127T 0.0324 (6)(4)
λs = 0.000127T + 0.0362 (5)
λs = 0.000103T + 0.0475 (6)
where ρ and ρ1 denote the apparent density and true density in g/cm3 , and φ is the porosity.
Figure
Figure 9. 9. Specimen
Specimen in the
in the high-temperature
high-temperature stage.stage.
The
The measured
measured density
density and and the calculated
the calculated porosity
porosity are shown
are shown in Tablein
2. Table 2. It
It can be can be see
seen
that in the low-temperature stage (373–573 K), the true density decreased from 0.791 g/cm 3
that in the low-temperature stage (373–573 K), the true density decreased from 0.791 g/cm
toto0.723 g/cm 3
0.723 g/cm. 3In this
. In stage,
this the the
stage, water and volatility
water in the in
and volatility intumescent coating escaped
the intumescent coating escape
and the mass of the coating decreased, whereas the volume remained unchanged. In the
and the mass of the coating decreased, whereas the volume remained unchanged. In th
high-temperature stage (673–1073 K), the apparent density decreased from 0.297 g/cm3
high-temperature stage (673–1073 K), the apparent density decreased from 0.297 g/cm3 t
to 0.074 g/cm3 , and the true density decreased from 0.611 g/cm3 to 0.240 g/cm3 . The
0.074 g/cm
coating
3, and the true density decreased from 0.611 g/cm3 to 0.240 g/cm3. The coatin
started to expand, the mass decreased, and the volume continued to increase.
started
The to expand,
apparent densitythe andmass decreased,
true density and
of the the volume
expanded continued
coating to increase.
both decreased with theThe appar
ent density
increasing and true density
temperature. of thethe
In addition, expanded
porosity ofcoating both decreased
the intumescent coatingwith the increasin
increased
temperature.
from 0.514 to 0.722In addition, the porosity
in the temperature rangeof(673–973
the intumescent
K), whereascoating increased
it decreased from 0.514 t
from 0.722
to0.722
0.692ininthe
the temperature
temperature range range(973–1073
(673–973K). K),The is due to
whereas the intumescent
it decreased fromcoating’s
0.722 to 0.692 i
oxidation at high temperatures.
the temperature range (973–1073 K). The is due to the intumescent coating’s oxidation at hig
temperatures.
Figure
Figure10.
10.Physical
Physicalmodel
modelofofthe
theCFST
CFSTstructure under
structure the
under protection
the ofof
protection intumescent coating.
intumescent coating.
3.2.
3.2.Governing
GoverningEquation
Equation
The
The thermalresponse
thermal responseofofthe
theCFST
CFSTstructure under
structure under the protection
the of of
protection thethe
intumescent
intumescent
coating in the fire is a transient heat-transfer process, and the numerical simulation fol-
coating in the fire is a transient heat-transfer process, and the numerical simulation follows
lows the three-dimensional
the three-dimensional unsteady
unsteady heatheat conduction
conduction differential
differential equation:
equation:
∂∂ ∂∂ ∂T ∂∂
∂T ∂T
∂T ∂∂ ∂T∂T
((Tc ρ )
Tcρ) = = λ
λ +
+ λ λ +
+ λ λ (8)(8)
∂∂t
t ∂∂xx ∂x
∂x ∂∂yy ∂y
∂y ∂∂zz ∂z
∂z
where
whereTTmeans
meanstemperature
temperatureininK,K,c cisisthe
thethermal
thermalcapacity
capacityininJ/(kg⋅K), ρ isρ the
J/(kg·K), true
is the density
true density
from
fromthe
thedensity
densityexperiment
experimentininkg/m
kg/m 3 , x,
3, x, y, y,
z denote thethe
z denote coordinate
coordinate system
systemin in
mm and t t
and
represents
representsthe
thetime
timeinins.s.
The temperature change along the axial direction of the CFST structure was much
smaller than that along the radial direction of the structure, so the temperature change
along the axial direction of the structure can be ignored:
∂ ∂T
λ =0 (9)
∂z ∂z
∂ ∂ ∂T ∂ ∂T
(Tc ρ ) = λ + λ (10)
∂t ∂x ∂x ∂y ∂y
Buildings 2022, 12, 1014 The solution to Equation (10) requires the thermal property parameters of the intu-9 of 18
mescent coating and the CFST structure. The thermal property parameters of the intumes-
cent coating in this study were obtained through the experiments, and the thermal prop-
erty parameters of the CFSTchange
The temperature were taken
alongbased on GB
the axial 50936-2014
direction [40].
of the CFST structure was much
smaller than that along the radial direction of the structure, so the temperature change
3.3. Initial
alongand
theBoundary Conditions
axial direction of the structure can be ignored:
The initial condition is as follows:
∂ ∂T
T ( x∂z
, y ) t = 0∂z= T0= 0
λ
(11)
(9)
Substituting
where T0 denotes Equation
the ambient (9) into (8), with
temperature the governing
a value ofequation
293 K. for the thermal response of
the CFST structure under the protection of the intumescent
Solving the above heat-transfer governing equation also requires coating boundary
is obtainedcondi-
as follows:
tions. When the CFST structure is under fire, it is usually understood that external heat is
∂ ∂ ∂T ∂ ∂T
transferred to the structure by means ( Tcρ)of=thermal +
λ convection λand radiation, as shown in (10)
∂t ∂x ∂x ∂y ∂y
Figure 11. The boundary conditions can be expressed as:
The solution to Equation (10) requires the thermal property parameters of the intumes-
q = qconv + qrad (12)
cent coating and the CFST structure. The thermal property parameters of the intumescent
wherecoating
q, qconv in this
and qradstudy were respectively,
represent, obtained through the heat
the total experiments, and theheat
flux, convective thermal
flux property
and
parameters
radiative heat flux.of the CFST were taken based on GB 50936-2014 [40].
The convective heat flux is defined as:
3.3. Initial and Boundary Conditions
(
qconv = h f T f − Ts
The initial condition is as follows: ) (13)
where hf is the convective heat-transfer coefficient in W/(m2 ·K), the value of hf is in the
Buildings 2022, 12, x FOR PEER REVIEW 11 of 20
range from 10 W/(m2 ·K) to 20 W/(m2 ·K) and 15 W/(m2 ·K) is adopted in the numeri-
cal simulation according to Gillet [42]. Tf is the gas temperature, and Ts is the surface
temperature of the intumescent coating.
Figure 11.TheBoundary
radiativeconditions
heat fluxofisthe numerical
defined model.
as [43]:
According to the boundary conditions, 4 temperature
4
qrad = ε systhe
σ Tgasf − T s Tf is the main external (14)
factor affecting the heat transfer into the structure. Therefore, it is important to describe
thewhere
temperature-rise
εsys denoteshistory of the emissivity
the system gas temperature
with aaccurately. Various
value of 0.75, andfire
σ isscenarios have
the Boltzmann
some differences
constant with a in the of
value 5.67 × 10−8 W/(m
temperature-rise 2 ·K4 ).The fire scenarios generally have two
models.
forms: (1) fire dominated
According by hydrocarbon
to the boundary substances,
conditions, the gas which is usually
temperature Tf iscaused
the mainby petro-
external
factor
leum; (2)affecting the heatby
fire dominated transfer
fibrous into the structure.
substances, which Therefore, it iscaused
is usually important to describe
by wood, paperthe
andtemperature-rise
textiles. history of the gas temperature accurately. Various fire scenarios have some
differences in the substances
For the fibrous temperature-rise
fire, themodels.
ISO 834Themodel fireisscenarios
a commonlygenerally have two
used model and forms:
can
be(1) fire dominated
expressed as: by hydrocarbon substances, which is usually caused by petroleum;
(2) fire dominated by fibrous substances, which is usually caused by wood, paper and textiles.
For the fibrous substancesTfire, the ISO 834 model t isa commonly used model and can
f = T0 + 345lg + 1 (15)
be expressed as: 7.5
t
Figure 12 shows the gas temperature T f = T0 +curve
345lg used + 1 (15)
7.5 in the simulations; it can be seen
from the figure that the gas temperature increased with time.
Figure 12 shows the gas temperature curve used in the simulations; it can be seen from
the figure that the gas temperature increased with time.
1400
1200
Gas temperature(K)
1000
800
600
400
200
0 2000 4000 6000 8000 10000
Time(s)
T (K) 293 373 473 573 673 773 873 973 1073
λs (W/(m·K)) 0.10 0.14 0.19 0.24 0.29 0.34 0.39 0.44 0.49
2 2
λ g φ 3 + 1− φ 3 λ s
λeq = λs 2 2
λ g φ 3 − φ + 1− φ 3 + φ λ s
(17)
8
λ g = 4.815 × 10−4 T 0.717 + dεσT 3
3
where λs denotes the intumescent coating’s thermal conductivity, λg denotes the air thermal
conductivity, and λeq denotes the equivalent thermal conductivity. φ indicates the porosity,
d is the average diameter of the pore with a value of 3.495 × 10−3 m, and ε is the intra-pore
emissivity with a value of 0.8. The equivalent thermal conductivity of the intumescent
coating at different temperatures is calculated by Equation (17). The results are shown
in Table 4.
T (K) 293 373 473 573 673 773 873 973 1073
λs (W/(m·K)) 0.10 0.14 0.19 0.24 0.29 0.34 0.39 0.44 0.49
λg (W/(m·K)) 0.04 0.06 0.08 0.12 0.18 0.25 0.34 0.45 0.59
φ 0.514 0.655 0.705 0.722 0.692
λeq (W/(m·K)) 0.10 0.14 0.19 0.24 0.23 0.28 0.35 0.44 0.56
(c) Assuming that the thickness of the intumescent coating remains unchanged, the
thickness change is equivalently converted into the thermal conductivity change by
Equation (18). As a result, the input values in the simulation calculation are obtained,
which can be seen in Table 5:
T (K) 293 373 437 573 673 773 873 973 1073
n 1 1 1 1 3.16 5.35 7.08 7.13 5.71
λ0eq (W/(m·K)) 0.10 0.14 0.19 0.24 0.07 0.05 0.05 0.06 0.10
λeq
λ0eq = (18)
n
where λ0eq represents the input value in the numerical simulation, n denotes the expansion
rate from the expansion experiment, and the value is displayed in Table 1.
Table 5. The input value in the numerical simulation.
T(K) 293 373 437 573 673 773 873 973 1073
n 1 1 1 1 3.16 5.35 7.08 7.13 5.71
Figure 15. Temperature variation over time with different initial thicknesses.
Figure 16. Temperature variation over time with different expansion rates.
Figure 17. Temperature variation over time with different intra-pore emissivity.
Table 11. Temperature-rise rate with different intra-pore emissivity at different times.
Figure 18. Temperature variation over time with different reaction heats.
Table 13. Temperature-rise rate with different reaction heats at different times.
4. Conclusions
Expansion performance and thermal physical property experiments were carried
out to obtain the basic data of intumescent coating at high temperatures. The thermal
response model of the CFST structure under the protection of intumescent coating in a fire
was established, and the effects of initial thickness, expansion rate, intra-pore emissivity
and reaction heat on the structure’s temperature were discussed based on the numerical
simulation. The following conclusions could be drawn:
(1) The thickness of the intumescent coating stayed the same at low temperatures, then
increased rapidly with the increasing temperature, finally decreasing due to oxida-
tion at high temperatures. The thermal conductivity increased with the increasing
temperature, and the calculation equations at different temperature were obtained.
(2) The initial thickness had a positive effect on the intumescent coating’s thermal insu-
lation performance. As the initial thickness increased, the thermal insulation perfor-
mance improved.
Buildings 2022, 12, 1014 17 of 18
(3) The expansion rate had a remarkable effect on the intumescent coating’s thermal insu-
lation performance, but the effect was limited when the expansion rate increased to a
certain level. In the material formulation design, appropriately increasing the quantity
of the foaming agent could effectively improve the thermal insulation performance.
(4) The intra-pore emissivity had a negative effect on the intumescent coating’s thermal
insulation performance. Thermal radiation in the porous carbon layer strength-
ened the coupled heat transfer. In the material-formulation design, specific fillers
could be used to decrease the intra-pore emissivity, thereby improving the thermal
insulation performance.
(5) The reaction heat hd a slightly positive effect on the intumescent coating’s thermal
insulation performance. In the material formulation design, modifying the com-
ponents could strengthen the heat-absorption effect, thus improving the thermal
insulation’s performance.
Author Contributions: Conceptualization, Y.H. and M.L.; methodology, L.Z.; software, L.Z.;
validation, Y.H., L.Z. and M.L.; formal analysis, L.Z.; investigation, Y.H.; resources, L.Z.; data
curation, L.Z.; writing—original draft preparation, L.Z.; writing—review and editing, L.Z.; visualiza-
tion, L.Z.; supervision, Y.H.; project administration, M.L.; funding acquisition, M.L. All authors have
read and agreed to the published version of the manuscript.
Funding: This research received no external funding.
Conflicts of Interest: The authors declare no conflict of interest.
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