On-Site Intumescent Coatings

Engineered Fire Protection Delivered Under Live Site Conditions

On-site intumescent coating protects installed structural steel through disciplined processes, controlled application and continuous verification. Every stage is managed to ensure the applied system performs exactly as tested, specified and approved.

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Video Explainer

On-Site Intumescent Coatings Explained

This short video explains how intumescent coatings are applied to structural steel on live construction sites, including environmental control, WFT measurement, and quality assurance.

Watch Explainer Video

Close-up of rusted and corroded structural steel with visible rivets and flaking paint.

Assessment

Steel Condition Determines the Preparation Method

The existing condition of installed structural steel is assessed on site to determine the correct preparation approach. Corrosion, mill scale, residual coatings and surface contamination are evaluated to establish the preparation method required to achieve reliable adhesion and compliant fire-protection performance.

Preparation methods are selected to align with manufacturer requirements, fire-rating specification and site constraints.

Application

Airless Spray for Uniform Coverage and WFT Control

Intumescent coatings are applied using professional airless spray systems to achieve consistent film build across all steel profiles, including complex geometries, connections and boxed sections. Controlled spray application ensures uniform coverage, accurate Wet Film Thickness and repeatable results to specification.

Consistent coverage across all steel profiles

Real-time Wet Film Thickness control

Reduced overspray and material waste

Application & Environment

Controlled Application and Environmental Assurance

Pre-install intumescent coatings are applied using tightly controlled methods to ensure accuracy, consistency and compliance. Application technique and environmental conditions are managed together, allowing precise Wet Film Thickness control, predictable curing and fully verifiable fire-protection performance.

01

Application

Airless Spray for Uniform Coverage and WFT Control

Intumescent coatings are applied by airless spray to achieve uniform coverage and controlled film build across every face, edge and profile of the steel member. Application is carried out in defined stages and passes, ensuring specified Wet Film Thickness targets are achieved without over-application or defects.

This method supports predictable curing, consistent fire performance and clean handover documentation.

02

Environmental Monitoring & QA

Conditions Logged and Verified Throughout Application

Environmental conditions are monitored continuously during pre-install application. Substrate temperature, ambient temperature, relative humidity and dew point are recorded and maintained within manufacturer-specified limits.

Environmental logs form part of the project compliance record, alongside WFT measurements and product traceability data.

Environmental Control

Conditions Monitored and Maintained Throughout Application

Environmental conditions have a direct impact on adhesion, curing and fire-protection performance. Ambient temperature, substrate temperature, relative humidity and dew point are monitored before and during application to ensure all works remain within manufacturer-specified limits.

Ambient temperature maintained within specification

Substrate temperature verified prior to application

Relative humidity and dew point monitored continuously

All environmental readings are recorded as part of the project quality assurance file, providing evidence that application conditions met compliance requirements.

Hand wearing a black glove holding two digital meters displaying temperature and humidity readings indoors.

Worker in protective gear and respirator spraying white intumescent fireproof coating on metal beam in industrial setting.

Wet Film Thickness Verification

Fire Performance Confirmed During Application

Wet Film Thickness is monitored continuously throughout spraying using calibrated gauges. Readings are taken across all coated surfaces to confirm the specified build is achieved. Any deviation from specification is corrected immediately to maintain system integrity and fire-rating compliance.

Gauges checked and calibrated before each application phase
Readings logged at defined intervals
Immediate corrective action where required

Indoor construction site with exposed concrete ceiling, white brick walls, yellow ladder, ventilation duct, and scattered tools on the floor.

Ventilation & Containment

Protecting Operatives, Surroundings and Coating Performance

Ventilation and containment are actively managed throughout application. Airflow is controlled to maintain air quality for operatives and support coating performance, while containment measures protect adjacent trades, finishes and occupied areas on live sites.

Airflow managed to support coating performance and safety

Containment deployed where required

Air quality monitored throughout works

Two workers in high-visibility gear and helmets operating red Skyjack scissor lifts inside a large industrial warehouse.

Access & Coordination

Safe Access Selected for Each Phase of Work

Access solutions are selected based on task requirements, steel geometry and site conditions. MEWPs, scaffolding or secure platforms are used as appropriate, with works sequenced alongside other trades to maintain safety, efficiency and programme continuity.

Access method selected to suit environment and task

Application sequenced with other site activities

Safe positioning maintained at all times

Health & Safety

Worker wearing protective suit, gloves, and mask spray painting a white fireproof coating on ceiling beams.

Inspection & Quality Assurance

Verification Embedded at Every Stage

Inspection is embedded throughout the application process. Each stage is checked and documented before progressing, reducing the risk of defects and ensuring consistency across the installed system. Quality records form part of the final compliance documentation issued at project completion.

Surface Preparation Methods for Structural Steel

Different substrate conditions require different preparation techniques. We assess corrosion levels, existing coatings and site constraints to specify the most appropriate method for compliance and long-term performance.

All Prep Methods