On-Site Intumescent Coating at P&G Tilbury

Completed white intumescent-coated steel frame inside the P&G Tilbury facility.

Intumescent coating works to newly installed structural steel within a live manufacturing facility, coordinated around production and site-access requirements.

End client: Procter & Gamble
Delivered via: Millcroft Services
Location: Tilbury / Grays, Essex
Required fire-resistance period: 60 minutes
Completed: September 2025
Programme: Six days
Primed structural steel frame before intumescent application at P&G Tilbury.
Overview of primed steel ready for intumescent

The project requirement

The works formed part of a new internal build at Procter & Gamble’s Tilbury facility, supporting the installation of a control room and associated plant infrastructure.

The accepted project information identified a 60-minute fire-resistance requirement for the relevant structural steel.

Coating steel within a live manufacturing facility

The facility remained operational while the work was carried out. Access, segregation and coating activities therefore had to be coordinated with production schedules, permit-to-work arrangements and the site’s operational restrictions.

Our scope of work

Our scope covered local preparation to the pre-primed steel, application of the specified intumescent coatings and installation of the decorative finish.

The package included columns, beams, cellular beams and bracing associated with the new internal structure.

Testimonial
Thank you Myles and team for all your hard work on this one. It wasn't easy working around the schedule but you got it done without causing any further issues. It was a pleasure to work with you.
Chris
Project Manager, Millcroft Services

Preparation and coating application

The steelwork had been primed before our arrival. We carried out light mechanical preparation where required, then applied the specified Thermoguard Thermocoat WI and WO products by airless spray to the relevant members.

A decorative topcoat completed the visible coating build-up.

The works were completed within the facility’s permit-to-work and segregation arrangements, with the application programme coordinated around the agreed site working windows.

The outcome

The coating package was completed over six days and coordinated around the live manufacturing environment.

This allowed the wider control-room and plant installation to progress while meeting the project’s agreed working arrangements.

White intumescent-coated beams and columns inside the live manufacturing facility.
After intumescent coating was applied with airless sprayer
Close-up of a bolted steel connection with a completed white coating finish.
Close up of finish on intumescent coating

Structural steel coating within the live facility

The photographs show the pre-primed steel before application, the coating process and the completed finish across the new internal structure.

Need coating works planned around live operations?

Send us the project specification, steel schedule and access constraints. We can review the information and plan an on-site preparation and application approach around your operational requirements.

Illustration of a person in protective gear holding a spray gun, set against overlapping red and green circular backgrounds.
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Gallery

Pictures throughout the project.

Graco 695 XT airless sprayer with a yellow bucket in an unfinished industrial interior with metal framing and construction equipment.
Hand in black glove holding a blue infrared thermometer showing 20.1°C and a black temperature and humidity meter showing 18.5°C, 73.2% relative humidity, and 13.6°C dew point.
Interior construction site with yellow steel support beams surrounded by red safety barriers and exposed ceiling ducts and wiring.
Selected Projects

Selected Structural-Steel Projects

Examples of intumescent application across commercial, refurbishment and live working environments.