Development Of Novel Intumescent Fire-Resistant Board For 2-Hour Fire-Rated Door

Jong, Jessica Kwang Yin (2021) Development Of Novel Intumescent Fire-Resistant Board For 2-Hour Fire-Rated Door. Master dissertation/thesis, UTAR.

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Abstract

Fire door is a crucial development for many buildings’ fire safety protocol today. One of the many reasons is that fire door can provide valuable time for evacuation during fire outbreak and to prolong enough time before the building collapse. Intumescent fire protective materials provide a protective barrier for the most efficient utilization of a wide variety of passive fire protection systems at the recent development too. Therefore, this experimental research focuses on the essence of fire insulation in order to sustain the performance of fire protection and materials properties of fire-rated door that is developed and fabricated with the utilization of water-based intumescent binder (W-IB) as the core of the fire door. For this experimental research, there were five types of water-based intumescent binder (W-IB) formulations that were formulated and evaluated through various designed testing methods in terms of fire protective performances (e.g., Bunsen burner test, furnace test), mechanical properties (e.g., weight load test, adhesion strength test), chemical test (e.g., freeze-thaw cycle test, static immersion test), physical test (e.g., FTIR test, SEM/EDX test), and thermal properties (e.g., TGA/DTG test). After that, the W-IB formulations were then mixed with vermiculite and perlite to construct and fabricate firerated door prototypes. Furthermore, the fabricated door prototypes were conducted and evaluated by small-scale fire test and three-point flexural test. From all these tests, it showed that the best fire protective performance inventive fire-rated door prototype 2 (P2) with a low density of 617.21 kg/m3 showed an outstanding fire-resistance rating was selected and compared with the commercial gypsum board (GB) fire-rated door with a density of 729.56 kg/m3 under temperature rise test and fire endurance test. From the result obtained, prototype 2 (P2) is lighter by 18.2 % than GB and during defending fire outbreaks at the hottest zone (T1) up to 120-minute (2 hours) fire test, P2 only reached 95.7 ºC whereas GB exceeded 169.1 ºC. Therefore, P2 is a better material comparatively with respect to fire performances. During these testing methods, it was noticed that this novel fire-rated door incorporated with the addition of selected formulating intumescent binder was consistently proven to be more effective and efficient in preventing fires with respect to its sustainability and maintaining its technical integrity by surviving a fire resistance throughout the period of 2-hour fire test.

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