Intumescent Coating Systems Dulux Protective Coatings
Application Guideline for FirePro® 9300 and
FirePro® 9310
Table of Contents
1.0 Epoxy Systems 1
2.0 Surface Preparation 1
2.1 Abrasive blast clean 1
2.2 Secondary surface preparation on site 1
2.3 Power tool cleaning 2
3.0 Primers 2
3.1 Primers applied to abrasive blast cleaned mild steel 2
3.2 Primers applied to galvanized steel, tie coats and bolted connections 2
4.0 Top Coats 2
5.0 Application 3
5.1 Equipment 3
5.2 Procedure 3
6.0 Quality of Finish 4
6.1 Definitions as set out in SCI P160 (Blue Book) 4
6.2 Improving the quality of finish 4
6.3 Dry film thickness measurement 5
6.4 Paint film thickness acceptance criteria 6
7.0 Repair Areas 6
7.1 Repairs to top coat only 6
7.2 Repairs to intumescent coating and top coat 6
7.3 Repairs to primer, intumescent coating and top coat 6
1.0 Epoxy Systems
Epoxy based coatings due to their durability and fast cure are frequently applied off site in paint yards and at steel fabricators, these
coatings contain virtually no solvents and have very low VOC’s. As the epoxy intumescent coatings are chemically cured top coats they
can be applied with relative ease. These coatings can reduce the time required for applying the complete coating system.
Epoxy based chemically cured intumescent coatings are the most durable intumescent coating type for all environments.
C1-C3 Environments
For these environments a primer is not required, FirePro® 9300 and FirePro® 9310 can be applied directly to abrasive blast cleaned
steel, top coats are used where there is a specific colour requirement. FirePro® 9300 and FirePro® 9310 are light grey in colour
and will chalk and fade when exposed to UV light. Use a weatherable top coat if required for appearance and UV resistance.
C4-C5 Environments
For more corrosive environments an epoxy primer is required prior to the application of FirePro® 9300 and
FirePro® 9310, and a final polyurethane or fluoropolymer top coat.
Galvanized Steel
An approved epoxy primer is required prior to the application of FirePro® 9300 and FirePro® 9310.
2.0 Surface Preparation
2.1 Abrasive blast clean
Intumescent coatings are applied to structural steel that has been dry abrasive blast cleaned in accordance with
Sa 2.5 per section 4.2 of AS 1627.4 with reference to visual standard ISO 8501-1 Sa 2.5. A uniform angular anchor
surface profile of 40-70µm is recommended.
2.2 Secondary surface preparation on site
If there is an extended time between application of the primer and the intumescent, it is important several steps
be followed for long term performance to occur:
• Surface contamination such as chalking, debris collection and any collected oils and/or greases are washed off the surface utilizing
Gamlen CA1, following all instructions laid out in the product data sheet.
• If zinc oxides/zinc hydroxides, oxidation, staining, and/or other insoluble contaminate are found to be present on the surface after
cleaning, it must be fully removed by mechanical means.
If the maximum recoat time has been exceeded, the primed surface must be thoroughly and uniformly scarified. The preferable method
of scarification is by utilizing abrasive blasting with a fine abrasive. The method of blast cleaning and the media to be used is ultimately
to be selected by the contractor based on their experience and confidence in the capabilities of their equipment and components.
However, it is a good practice for the contractor to contact their abrasive supplier for information regarding the efficacy of the abrasive
to be used. Good mechanical adhesion is dependent upon the surface preparation being performed correctly. Dulux requires a clean,
dry and contaminate free surface that is uniformly dulled, profiled and free of any fractured coating. Below is the suggested procedure:
• Clean all surfaces to be scarified before and after the surface preparation in accordance with AS 1627.1 “Removal of oil, grease and
related contamination”. Method chosen is to be contingent on specifier approval.
• The prime coating must be thoroughly and uniformly abrasive sweep blasted. The use of fine abrasive and reduced nozzle pressure
is suggested. Oxidation, staining, and/or other insoluble contaminate on the prime coat must be removed.
• Abrasive blast test patches are further suggested to determine whether the abrasive and nozzle pressure selected will achieve the
desired effect.
• If any areas of rust exist, then the areas must be prepared in accordance with the original specification.
• All edges of remaining sound, tightly adhering coating should be feathered back (beveled) to create a smooth transition from the
substrate to the coatings surface. The coating maybe considered tightly adhering if an edge cannot be lifted with a dull putty knife.
Any transition margins between the prime coat and exposed steel substrate should be feathered in, creating a smooth transition.
• Any fractured prime coat should be removed, the surface prepared per the original standard and recoated per the
original specification.
• To a clean, dry, contaminate free and properly prepared surface, apply the specified system at the specified film thickness.
If small or isolated areas only need to be addressed, these can be thoroughly and uniformly abraded by hand and/or power tools,
creating a uniformly dulled and profiled surface. Consult your local Dulux Representative for job specific surface preparation
recommendations for the issues being encountered on the project.
Intumescent Coating Systems Dulux Protective Coatings 1 Application Guideline for FirePro® 9300 and 9310
2.3 Power tool cleaning
This should only be used for small areas, usually for touch up and repair areas, care must be taken not to polish steel during this
method of preparation. In the small areas identified, prepare the substrate in accordance with SSPC SP-11, “Power Tool Cleaning
To Bare Metal”, Level 1. Consult your local Dulux Representative for further details.
3.0 Primers
3.1 Primers applied to abrasive blast cleaned mild steel
Primers shall be applied in accordance with the product datasheets and for use with intumescent coating the following maximum dry
film thickness (DFT) limits shall apply:
Approved Primers for FirePro® 9300 and FirePro® 9310 DFT
Durepon® EZP 75µm
Durepon® FRX 75µm
Zincanode® 402 75µm
Luxepoxy® 4 White Primer 50µm
Note: For C1-C3 environments FirePro® 9300 and FirePro® 9310 do not require primer, always refer to the project specification for the
correct coating system.
3.2 Primers applied to galvanized steel, tie coats and bolted connections
Clean and prepare the surface in accordance with AS/NZS 2312.2, Section 7.5.3, “Preparation for painting”.
If abrasive blasting is not possible following the degreasing process the surface should be abraded with 80-120 grit sandpaper and
then thoroughly cleaned before applying the primer.
In the same manner all nuts, bolts, and connectors shall be cleaned and degreased, followed by the application of the primer
listed below.
Approved Primer/Tie coat DFT
Luxepoxy® 4 White Primer 50µm
FirePro® 9300 and FirePro® 9310 should not be applied on mating steel connections. These areas, bolts and washer surfaces should
be neatly masked out before applying the intumescent coating.
4.0 Top Coats
Top coats need to be applied in accordance with the over coating times stipulated on the relevant intumescent
coating datasheet:
Approved top coats for FirePro® 9300 and FirePro® 9310 Recommended Minimum DFT
Luxathane® SPX 50µm
Luxathane® HPX 70µm
Weathermax® HBR and HBR Mio 100µm
Quantum® V90 and V92 75µm
The total top coat DFT should not exceed 150µm.
Intumescent Coating Systems Dulux Protective Coatings 2 Application Guideline for FirePro® 9300 and 9310
5.0 Application
5.1 Equipment
• Airless spray unit Graco® K60FH2 (60:1) or equivalent.
• 3/8” (9.5mm) or 1/2” (12.7mm) diameter material house, max 20m in length. If using 1/2” material line, the addition
of a 3/8” (2m) whip line is allowed.
• The use of a 3/8” non-restrictive SS swivel connection between the spray gun and the material line is recommended for ease of
application.
• Use a Graco® XHF direct feed spray gun w/ XHD RAC switch tip and guard or equivalent.
• Graco® 4500W/240v explosion proof inline heater and heater mounting kit - Graco® part numbers 243863 and 17V573
or equivalent (material temp at nozzle needs to be 35°C for proper atomisation).
• Spray tips / nozzle sizes
– FirePro® 9300: 482 - 584 microns (0.019 - 0.023”)
– FirePro® 9310: 533 - 584 microns (0.021 - 0.023”)
• Stainless Steel Hopper fitted to allow gravity feed of the coating to the pump.
• Heavy duty paint mixer with a large diameter (160mm). Use a double helical mixing blade and a power mixer similar
to an Intex® Mega Mixer AMX 620 to thoroughly and uniformly mix the material, scraping the side of the pail, folding the material
back into the body of the product while mixing.
5.2 Procedure
• Ensure all equipment is clean (Duthin® 450).
• Remove both the pump filter and the spray gun filter.
• Do not use a suction hose on the pump, a stainless steel hopper must be fitted to gravity feed the pump.
• During flushing with solvent prior to painting ensure there are no leaks.
• Ideal temperature of the material before spraying is 16-25°C. Min temp = 10°C and Max temp = 40°C.
• First mix component A until homogeneous and then add component B, ensure all of component B is used.
• It is recommended to decant the mixed product into a container and then remix material in the new container.
• The in-line heater is used to achieve an ideal temperature of 35°C at the spray tip. A higher temperature setting may be required
initially. Material should not be recirculated as heated material in mass will greatly reduce the useable life of the material.
• A pressure of approx. 200bar (3000 PSI) in the spray gun is required to achieve a good finish.
• After every 5 - 6 kits the equipment should be flushed with solvent. This is accomplished in two stages. First, Duthin® 450 or
CR Reducer (either new or filtered) is run through the pump for five minutes. Then a second flush is done, again for five minutes
using fresh Duthin® 450 or CR Reducer (this solvent can be used for the first flush cycle of the next flush cycle). After the end
of a work shift, the pump is flushed as stated. This time, after the second flush, the lower end of the pump is disassembled and
thoroughly cleaned to remove all traces of coating material. It should be noted that the amount of flushing needed is dependent on
temperatures and extended spray times.
• Complete cleaning is required at the end of every shift/day.
• Ensure there is sufficient distance between the nozzle and the steel substrate to avoid a displacement of the thick coating by the
spray pressure.
• Regular checks of wet film thickness should be done in order to achieve the specified coating thickness for the relevant steel item.
Intumescent Coating Systems Dulux Protective Coatings 3 Application Guideline for FirePro® 9300 and 9310
6.0 Quality of Finish
6.1 Definitions of Finish as set out in SCI P160 (Blue Book)
The aesthetics of an intumescent finish can vary depending on application techniques and the nature of a project. The standard of
finish required by the client should be included in the coating specification and agreed upon with the applicator before commencing
application. Samples or test patches should be prepared by the applicator and agreed upon by interested parties. Typically, the range
of finishes are defined as:
(i) Basic finish:
The coating system achieves the required fire performance and corrosion protection performance, but is not required to achieve
any requirements for standard of finish.
(ii) Decorative finish:
In addition to the requirements for (i) above, a good standard of cosmetic finish is generally required, when viewed from a distance
of 5m. Minor orange peel or other texture resulting from application or localised repair is acceptable.
(iii) Bespoke finish:
In addition to the requirements for (i) above, the coating finish is required to have a standard of evenness, smoothness and gloss
agreed between the specifier and contractor. When agreeing a bespoke standard of finish, the specifier and contractor should
take account of the effects of steel size, section shape, design complexity and the required period of fire resistance.
The Contractor shall provide for a basic finish unless otherwise noted in the contract.
6.2 Improving the quality of finish
In many cases the applicator can avoid sanding to remove film imperfections such as stipple and wet film gauge marks by following
these steps while the applied coating is in a specific state of cure.
1) At an ambient average temperature of 25˚C, allow the painted structure to “tack up” for 45-60 minutes before manipulating the
applied film.
a) This time-frame will vary depending upon the environmental conditions. In an inconspicuous place make sure the film is ready
first before proceeding.
i) If coating comes back onto the roller-cover it is not ready.
ii) If the roller cover sticks to the coating, is hard to roll (heavy drag associated with rolling), leaves roller nap in the film and/or
pulls sticky material back onto the roller cover the cure has gone too far.
2) Using a 5mm x 100mm shed resistant roller cover lightly wetted (remove any dripping excess before beginning) with xylene,
roll back forth over the area which needs to be smoothed out, ensuring to not overwork the area.
a) In some cases, a wetted flat blade and/or wetted trowel (with xylene) may be found to better address specific areas better than
a roller cover.
b) Refresh the tool being used with xylene as needed to maintain a lightly wetted state. Remove any coating residue from the tool
as needed with a clean rag as needed.
Note, Dulux FirePro® products should not be thinned during application. The above instructions for solvent are for wetting tools and
preventing a sticking of the coating to tools when they are being used on an already applied coating.
Intumescent Coating Systems Dulux Protective Coatings 4 Application Guideline for FirePro® 9300 and 9310
6.3 Dry film thickness measurement
Measurement procedure/guidance notes.
Calibration:
In accordance with ISO 2808:2001 or SSPC PA 2, calibration of the DFT gauge should be carried out following the manufacturer’s
instructions using a smooth plate (similar in composition to the substrate being measured) at least 1.2 mm thick. The calibration should
be checked using shims above and below the expected DFT.
ISO 2808 refers to a figure of 25 μm as a correction factor for blast profile. It is intended to use this correction factor for measurements
of all coating thicknesses above 50 μm nominal. When using SSPC PA 2, refer to Appendix 8 on guidance to adjust for surface profile.
Calibration checks should be performed prior to carrying out measurements, in the environment in which the measurements are to be
taken. During a series of measurements, the calibration should be rechecked on a regular basis.
Measurement procedure:
Tests shall be carried out in accordance with the following:
(i) I Sections, Tee Sections and Channels
Webs: Two readings per metre length on each face of the web.
Flanges: Two readings per metre length on the outer face of each flange. One reading per metre length on the inner faces of each
flange.
(ii) Square and Rectangular Hollow Sections and
Angles: Two readings per metre length on each face.
(iii) Circular Hollow Sections.
Eight readings per metre length evenly spread around the section.
(iv) Where members are less than 2 m in length, three sets of reading shall be taken, one near to each end and one at the centre
of the member. Each set shall comprise the number of readings on each face given by (i), (ii), or (iii) above, as appropriate.
(v) For Flat Plates take five readings per metre square
The proportion of items, or of the coated area, to be surveyed will need to be agreed between Dulux Protective Coatings and
the customer.
If defects are identified a more detailed survey may be appropriate.
Intumescent Coating Systems Dulux Protective Coatings 5 Application Guideline for FirePro® 9300 and 9310
6.4 Paint film thickness acceptance criteria
Intumescent coating schemes
These criteria are based on the required thickness as stated in the paint specification, advised by the applicator or from the FDE
loading schedule:
(i) The average dry film thickness applied to each element shall be greater than or equal to the specified nominal value. No more than
10% of the DFT readings should be below 80% of the recommended DFT.
(ii) The average measured dry film thickness on any face of any member shall not be less than 80% of the specified nominal value.
(iii) Dry film thickness values less than 80% of the specified nominal value are acceptable, provided that such values are isolated.
Where any single thickness reading is found to be less than 80% of the specified nominal value, a further two, or where possible
three, readings shall be taken within 150 to 300 mm of the low reading. The initial reading may be considered isolated if all the
additional readings are at least 80% of the specified nominal value. If one or more of the additional readings are less than 80% of
the specified nominal value, further readings shall be made to determine the extent of the area of under thickness.
(iv) All dry film thicknesses shall be at least 50% of the nominal value.
When measuring intumescent fire protected steelwork the mean must not exceed the maximum fire tested thickness for that type
and orientation/use/geometry of section.
Where possible the primer thickness should be determined prior to the application of the intumescent coating. This mean value
and the blast profile correction should then be subtracted from the primer and intumescent thickness, measured before the
application of any topcoat.
If it has not been possible to measure the primer thickness and the primer and intumescent thickness and hence determine the
intumescent thickness accurately then the specified nominal thickness for primer and topcoat may be used.
In either case the 50 and 80% values relate to the full primer (and topcoat) thickness plus 50 or 80% of the specified Intumescent
thickness.
i.e. Specification:
Primer = 25 μm, Intumescent = 1000 μm, Topcoat = 50 μm
50% value = Blast Profile + Primer + 50% Intumescent + Topcoat
600 μm = 25 + 25 + 500 + 50
80% value = Blast Profile + Primer + 80% Intumescent + Topcoat
900 μm = 25 + 25 + 800 + 50
7.0 Repair Areas
7.1 Repairs to top coat only
It is important that FirePro® 9300 and FirePro® 9310 are sanded in order to create a profile for the adhesion of the top coat. The edges
of the existing top coat should be feathered back to create a smooth surface for the best visible appearance. The repair should overlap
by at least 25mm onto sound existing top coat.
7.2 Repairs to intumescent coating and top coat
All areas where FirePro® 9300 and FirePro® 9310 are damaged, they must be re-instated to the specified DFT.
The intumescent coating must be abraded to create a profile for adhesion. Take care not to apply intumescent
coatings over the existing top coat. In accordance with the relevant datasheet and the applicable over coating time, apply the top coat
over lapping at least 50mm onto sound, properly prepared top coat.
7.3 Repairs to primer, intumescent coating and top coat
For areas that are damaged, and the substrate is exposed, see section 2.3 for surface prepartion recommendations. Once the surface
is clean only the bare substrate should be primed with the specified primer. Overlapping onto the existing primer is recommended,
but do not apply the primer on FirePro® 9300 or FirePro® 9310.
Once the primer is dry to overcoat apply the intumescent coating to the correct DFT and do not overlap onto the existing top coat.
In accordance with the relevant datasheet and the applicable over coating time, apply the top coat over lapping at least 50mm onto
sound, properly prepared top coat.
Intumescent Coating Systems Dulux Protective Coatings 6 Application Guideline for FirePro® 9300 and 9310
Intumescent Coating Systems Dulux Protective Coatings 7 Application Guideline for FirePro® 9300 and 9310
Australia
www.duluxprotectivecoatings.com.au
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New Zealand
www.duluxprotectivecoatings.co.nz
T 0800 800 424
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Any advice, recommendation, information, assistance or service provided by Dulux© Protective Coatings in relation to goods manufactured by it or
their use, including application, is given in good faith and is believed by Dulux© Protective Coatings to be appropriate at time of creation. Products
can be expected to perform as outline provided that application conditions and procedures are followed on relevant data sheets. Specific advice
should be sought from a Dulux Protective Coatings specialist, espically for more corrosive and demanding enviroments, to obtain a tailored and
appropriate solution.
March 2022
