Using scanning electron microscopy, x-ray diffraction and IR spectroscopy to study the ageing of intumescent fire-proof coatings

Introduction. The fire protection of metal structures is a relevant present-day problem; its solution implies better fire resistance performance of structures attainable through the application of intumescent fire-proof coatings whose service life expectancy is limited. Goals and objectives. Comprehensive studies of domestically made coating samples were performed to analyze the changes in the chemical composition of intumescent coatings containing ammonium polyphosphate, melamine, and pentaerythritol. The samples were exposed to artificial climatic ageing (3, 6, and 9 years). Methods. Optical and scanning electron microscopies were used to study the appearance of samples, the morphology of inclusions and the surface microstructure. X-ray diffraction and IR spectroscopy were employed to study the phase and structural states of samples, and the swelling ratio of fire-proof coatings was also examined. Results and discussion. It's been found out that the swelling ratio of samples goes down to a significant extent as the time progresses, and when the residual life of a coating reaches 30 %, the fire resistance limit of the structure goes down. Sample ageing is the reason for gradual phase composition changes due to the melamine content reduction by 40 %, ammonium polyphosphate content reduction by 15 % and redistribution of other components that change the microstructure of coatings, as well as their fire retarding properties. Conclusions. The changes, influencing the ability of a coating to maintain its fire retarding efficiency as declared by the manufacturer, take place in the course of operation of a coating exposed to external factors. The regularities, identified by virtue of this research, can be used to study the samples taken at fire-proofed facilities to identify deviations from the initial condition of a coating and to forecast its actual service life.