Fire-resistant materials have been a crucial component across industries like construction, aerospace, and automotive.
Although no material is completely fireproof, fire-resistant materials can slow fire’s expansion by lowering the temperature, forming a protective layer or self-extinguishing.
They ensure safety in buildings, vehicles, and clothing among others.
Significant progress has been made in developing these materials, driven by the need for improved protection, sustainability, and compliance with stricter safety standards.
The use of fire-resistance materials dates back to the days when people used clays, asbestos, and gypsum for safety.
The limitations of these materials include weight, cost and environmental impact.
However, industrial advancements and urbanization led us to a greater need for more effective solutions that incorporate advanced chemical formations and engineering techniques.
The latest developments in fire-resistant materials include innovations in polymers, composites, and coatings.
In modern construction, ensuring the safety and integrity of buildings during fires is paramount.
Steel rebar is a vital component in reinforced concrete structures as it provides tensile strength, and helps structures withstand stress.
However, under high temperatures, the strength of regular steel can diminish, compromising the structural integrity of the building.
According to Consegic Business Intelligence, the stainless-steel rebar segment is expected to be the fastest-growing CAGR from 2023 to 2031 due to its excellent durability, fire resistance, and structural performance.
Applying fire-resistant coatings can insulate the steel when exposed to heat.
Also, alloying elements and incorporating elements like chromium, molybdenum, and nickel in the steel composition enhance the heat resistance.
Fire-resistant glass is designed to withstand high temperatures and prevent the spread of flames and smoke.
Unlike regular glass, which shatters quickly under heat, fire-resistant glass maintains its integrity for a specified period, typically ranging from 30 minutes to several hours, dependent on its quality and rating.
There are several types of fire-resistant glasses including wired glass, ceramic glass, and intumescent glass.
They are essential in containing fires within a particular area, giving occupants more time to evacuate and firefighters more time to control the blaze.
Intumescent coatings when exposed to high temperatures, expand and form an insulating char layer that protects the underlying material from heat and flames.
Recent developments in coatings include the integration of nanotechnology, which enhances their performance.
Nano-clays, carbon nanotubes and graphene are integrated into these coatings to improve thermal stability, char strength and efficiency.
Also, modern intumescent formulations include ammonium polyphosphate, pentaerythritol, and melamine, which together create a robust and effective fire protection system.
Additionally, recent research has discovered that the optimal composition (EP/24APP/16Cu2O) with a 6/4 mass ratio of APP to Cu2O in EP significantly enhances fire safety.
A new fire-retardant acrylic paint called ‘FireCoat’ has been developed by Flame Security International (FSI) in collaboration with the University of New South Wales.
When applied as an undercoat to a house, the paint forms a thick, protective layer that deflects heat away from bushfires, reducing the temperature at the substrate surface to roughly around 25 to 30°C from 1000 to 1200°C.
These findings are pivotal for creating intumescent fire protection coatings and paints with high fire safety standards.
With growing environmental concerns, there has been a push towards developing sustainable fire-resistant materials.
Biomaterials derived from renewable sources such as plant fibres and biopolymers, are being explored for their fire-resistant properties.
For instance, researchers have developed fire-resistant composites using natural fibres like hemp, flax and jute combined with bio-based resins.
These materials offer a greener alternative to traditional fire-resistant materials and are being utilized in various industries.
Moreover, Australian scientists are researching the use of fungi as a non-toxic, biologically based alternative to toxic flame retardants in building materials.
They have successfully grown molasses-fed sheets of fungi, which could be used for fire-resistant cladding in construction or as leather-like textiles.
These bio-based substances aim to prevent tragedies like the 2017 UK Grenfell Tower fire.
The materials take advantage of the fire-resistant properties of mycelium, the root-like structure of fungi.
This research could lead to fireproof materials without hazardous plastics and chemicals.
Protective coatings come in various types, such as ceramic coatings, aerogels, hydrogels, and self-healing coatings, each serving a specific purpose.
Ceramic coatings, for instance, are specifically formulated for metal and composite surfaces to enhance their resistance to high temperatures and fires.
These coatings are typically crafted from materials like silicon carbide or aluminium oxide, creating a durable barrier that reflects heat and prevents structural degradation.
Aerogels are highly porous, lightweight materials known for their exceptional thermal insulation properties.
Silica aerogels have been enhanced with fire-retardant additives to improve their flame resistance.
These aerogels are used in applications ranging from building insulation to protection clothing for firefighters.
Furthermore, hydrogels are being recognized as an innovative solution for fire-resistant treatment, especially for fabrics.
These water-based gels can be strategically applied as a coating to form a protective char layer when exposed to flames.
Recent research has been dedicated to enhancing the durability and reusability of hydrogel coatings.
Self-healing materials represent an exciting breakthrough in the development of fire-resistant materials.
These innovative coatings have the ability to repair themselves after sustaining damage, thus ensuring the long-term preservation of their protective properties.
One promising approach that has emerged from recent studies involves the incorporation of microcapsules filled with healing agents, which are released upon cracking or exposure to heat.
High-performance fibres such as aramids, polybenzimidazole(PBI), and poly(p-phenylene-2,6-benzobisoxazole) (PBO) have become essential in applications requiring extreme fire resistance.
Aramis fibres, including Kevlar and Nomex, are renowned for their exceptional thermal stability and flame resistance.
They are widely used in firefighting gear, aerospace components, and military applications.
Advances in the chemical treatment and processing of aramids have further enhanced their flame-retardant properties and durability.
PBI and PBO fibres offer even higher levels of flame resistance than aramids.
PBI fibres do not burn or melt, making them ideal for high-temperature environments.
PBO fibres, with their superior tensile strength and thermal stability, are used in applications such as protective clothing for firefighters and industrial workers.
Fibre-reinforced polymers have gained popularity due to their excellent mechanical properties and lightweight nature.
The development of fire-resistance polymers involves the use of fire-retardant additives and resins.
Innovations in this area include the use of halogen-free flame retardants, which offer more environmentally friendly alternatives to traditional halogenated compounds.
Phase-change materials absorb and release thermal energy during phase transitions, providing thermal regulation and fire resistance.
When integrated into building materials, they can help maintain structural integrity by reducing temperature spikes during a fire.
Thermochromic materials change colour in response to temperature changes, providing a visual indication of heat exposure.
These materials can be used in coatings and fabrics to offer real-time monitoring of fire risk.
Thermoresponsive polymers, which alter their physical properties with temperature changes, are also being explored for their potential in fire protection.
Advancements in fire-resistant materials have made significant progress in enhancing safety across various applications.
The development of innovative fire-resistant solutions, from intumescent coatings and fibre-reinforced polymers to aerogels and bio-based materials, continues to evolve.
These materials not only offer essential protection against hazards but also contribute to sustainability and improved performance in construction, transportation, textiles, and electronics.
With ongoing research and technological advancements, the future of fire-resistant materials holds great promise, paving the way for even more significant developments that will further bolster safety and resilience within our built environment.
