India is undergoing an unprecedented wave of urbanisation, poised to accommodate over 600 million urban residents by 2031, according to UN-Habitat projections. This massive population shift is driving a vertical transformation of Indian cities, with high-rise buildings becoming an increasingly common feature of urban skylines. From commercial towers and residential skyscrapers to mixed-use developments and transit-oriented hubs, high-rises are seen as an efficient solution to the challenges of limited land, dense populations, and the demand for modern infrastructure.
In this race towards vertical expansion, steel’s qualities make it particularly well-suited for taller buildings where speed, reduced dead load, and architectural freedom are essential.
However, high-rises also magnify a critical challenge, fire safety. The risks associated with fire in tall buildings are significantly higher due to evacuation complexities, limited accessibility for firefighting operations, and the sheer number of occupants involved. While steel provides strength and adaptability, it suffers from rapid strength degradation when exposed to elevated temperatures. Studies have shown that steel can lose up to 50 per cent of its yield strength at around 550 °C, and up to 90 per cent by 1000 °C, severely compromising a building’s structural integrity during fire events.
To address these risks, the National Building Code of India (NBC) 2016 mandates that critical steel structural members in buildings, particularly high-rises, must achieve at least a 2 hour fire resistance rating. However, the implementation of this crucial safety measure is far from uniform. Ground reports and industry insights reveal that compliance levels vary widely across cities and projects, often affected by budget constraints, lack of technical awareness, or inadequate enforcement.
As India builds taller and faster, the conversation around fire safety for steel in high-rise buildings is no longer optional. Architects, structural consultants, fire engineers, fabricators, and developers must collaborate to bridge the gap between code provisions and on-ground realities. SSMB explores the technical, regulatory, and practical aspects of active and passive fireproofing of steel in Indian high-rise buildings, highlighting challenges, innovations, and the way forward for safer vertical cities.
Layers of Safety
In India, where rapid urbanisation is driving the need for larger and taller buildings, fire safety in steel high-rises presents a distinct set of challenges. Steel, unlike concrete, is highly vulnerable to elevated temperatures and loses its strength quickly when exposed to fire. This makes fire protection indispensable for maintaining the structural integrity of steel buildings during fire incidents.
Sameer Divekar, Executive Vice President, CP Kukreja Architects, highlights that essential fireproofing measures, such as concrete encasing, fire-resistant boards, or intumescent coatings, significantly affect project budgets and timelines. “Long approval procedures and the necessity to adhere to several regulatory standards frequently cause delays, and developers are reluctant to use cutting-edge fireproofing techniques because of the high costs of specialist materials,” he explains.
Shrirang Agrawal, Sr Structural Engineer, Arup, explains that protective coatings are essential since steel’s reaction to heat is an inherent property and cannot be altered. “One of the most common methods is applying intumescent paint, which comes in different specifications based on the required fire rating. In India, building codes require a minimum fire rating of two hours. Since intumescent paint can be expensive, other fire protection methods, like cement-based coatings, are also available as cost-effective alternatives,” he points out.
He further shares a practical approach to balancing costs and fire safety, especially for exposed structural steel elements. “Intumescent paint or other fire-resistant materials can be used on columns, while horizontal members like steel beams can be protected by installing a false ceiling with fire-resistant boards. This helps keep costs in check while ensuring good fire resistance,” he adds.
Praveena Panduranga, Head – Structural Steel Fireproofing, JSSL, draws attention to a critical but often overlooked challenge, the gap between fabrication and erection of steel. “Each primer has a specific overcoating interval, usually between two to four months. But by the time the steel is erected and fireproofing is applied — after slab casting, curing, and other site work — the primer may have deteriorated. This can weaken the bond between the fireproofing material and the steel, leading to extra surface preparation,” he explains.
He contrasts this with practices in the U.S., where steel is often delivered unpainted, allowing a light rust layer that actually helps vermiculite coatings bond better. “In controlled environments, where the steel will eventually be enclosed in false ceilings and air-conditioned spaces, this method works well. But in highly corrosive areas like Mumbai or Chennai, a primer is still necessary to prevent rust from becoming a bigger issue,” he says.
Panduranga suggests that careful planning of cycle times can help optimise this process. “In cities like Bangalore or Hyderabad, where corrosion isn’t a major concern, skipping the primer can help avoid unnecessary rework,” he advises.
Core Strength
When it comes to protecting steel structures from fire, two methods stand out: using high-grade stainless steel and incorporating sandwich panels. According to Deepak Monga, Fire Safety and Evacuation Expert, “At present, what most people use is SS304, but SS316 is the most recommended for its superior corrosion resistance and durability.” While SS316 comes at a higher upfront cost compared to SS304, he points out that it offers long-term savings by reducing maintenance and replacement needs. “Given the heightened exposure of steel structures to environmental elements and routine cleaning practices, which can involve soap and water, utilising SS316 steel is highly recommended,” he says.
Despite these advantages, the significant cost difference often leads to a preference for SS304. However, Monga stresses that adopting SS316 as the primary material, combined with measures like covering the steel to limit environmental exposure, can significantly enhance the structure’s durability and reduce maintenance requirements.
The installation process for both SS304 and SS316 remains the same, but he highlights an innovative solution to improve fire performance: the use of sandwich panels. “This method can potentially double the fire resistance of steel structures. It’s not about making the structure fireproof, but about heat resistance,” he explains. Sandwich panels delay heat transfer, allowing more time for evacuation during a fire, often slowing the spread of heat by up to two hours.
Beyond fire protection, they also improve insulation, structural durability, and cost-effectiveness, offering a sustainable long-term solution. “By investing in this innovative technology, builders and construction professionals can create more resilient and cost-efficient structures that stand the test of time,” Monga adds.
While these solutions apply effectively to general steel structures, a different approach is often taken for high-rise buildings. “Purely structural steel buildings, which are commonly seen in warehouses, factory buildings, and industrial structures,” says Agrawal. These types of buildings typically have simple, functional designs. However, when it comes to high-rises, composite construction may become more relevant. “In high-rise buildings, using concrete-filled tubes falls under composite construction. Structural steel members are encased in concrete, which provides additional fire protection,” he explains. The concrete cover, as specified by IS 456, varies depending on the fire rating. “For example, a two-hour fire rating requires a 40 mm cover for columns,” he adds.
While composite construction offers improved fire resistance, Agrawal notes that it also raises project costs. “Composite structures are usually chosen when a client wants optimised material usage and is open to using both steel and concrete. However, they can be more time-consuming and expensive compared to pure structural steel buildings, especially in high-rises,” he adds.
Safety Catch
Fire safety awareness in the construction industry has seen gradual improvement, yet challenges persist, not due to a lack of knowledge, but due to misplaced priorities. “No, they don’t lack knowledge or awareness,” says Monga. “Despite having access to expert guidance from engineers, architects, and technicians, developers and builders often prioritise cost savings over investing in high-quality steel fire resistance solutions.” This cost-cutting tendency often results in the use of lower-grade steel, compromising the level of fire protection available.
However, he highlights a positive shift. “The Government of Maharashtra, Fire Department, and Energy Department have initiated stringent fire safety measures, such as mandatory fire evacuation lifts and fire towers in high-rise structures.” While these measures are promising, he believes the key lies in strict adherence to standards and ensuring quality equipment installation.
He also emphasises the need for more proactive knowledge dissemination. “Empowering societies and builders with critical knowledge of fire safety and evacuation is crucial,” he says. He recommends that forums such as NAREDCO and CREDAI-MCHI organise regular training sessions led by fire safety and evacuation experts. He advocates for these sessions to move beyond mere compliance talks to focus on life safety, covering topics like fire safety protocols, evacuation procedures, hands-on equipment training, and emergency response planning. “The focus should shift from merely discussing fire safety to emphasising the broader importance of life safety,” he adds.
According to Monga, developers bear a critical responsibility when it comes to equipping their security personnel. “Developers have a critical responsibility to ensure that their security guards receive comprehensive training in firefighting, evacuation procedures, and fire safety protocols. Regrettably, this essential requirement is often overlooked,” he says. He also stresses the need for dedicated Emergency Response Teams (ERT) in every building, whether under construction or already occupied. “By having a well-trained ERT, developers can significantly enhance the safety and well-being of occupants, visitors, and staff,” Monga asserts.
From a design and engineering standpoint, Agrawal states that material compliance itself is not the main obstacle. “Compliance with any material isn’t a major issue because design follows established code guidelines,” he says. For example, he points out that structural steel high-rise buildings are entirely feasible within the existing regulatory framework. “It’s not a question of whether it can be done but rather how it is designed.”
However, Agrawal highlights that challenges arise when project sites span different seismic zones. “In such cases, it depends on how the structural system is framed and designed,” he explains. The complexity varies based on the chosen structural system, be it a 100 per cent shear wall system, a dual system, or one employing special moment-resisting frames or concentric braced frames. “Ultimately, there isn’t a fundamental challenge in meeting code compliance—it’s about making the right design choices to align with the regulations,” he adds.
Despite this technical feasibility, Divekar observes that regulatory implementation still poses difficulties. “High-rise fire safety is supported by India’s regulatory framework, which is governed by the National Building Code (NBC) 2016,” he says, “however, compliance is still difficult because of variations in enforcement among states and municipalities.”
Divekar highlights that the fire safety approval process is often time-consuming, involving multiple agencies and delaying projects. More concerning is the tendency to treat fire safety compliance as a one-time formality. “There is a propensity to view compliance as a one-time obligation rather than a continuous one, which might result in violations of fire safety regulations,” he notes. According to him, strengthening the system would require “stricter audits and enforcement, combined with a more standardised and centralised approval structure,” which could significantly improve fire safety across the country.
Testing the Limits
Ensuring the fire safety of steel buildings in India remains a significant challenge, with experts highlighting gaps both in infrastructure and attitude.
According to Divekar, at present, there are very few accredited laboratories capable of carrying out full-scale fireproofing system assessments. Most existing facilities only offer testing in controlled environments, which, while useful, do not accurately replicate real-life fire situations, especially in congested urban contexts.
He adds, “Post-construction fire safety audits are not as thorough as they ought to be, which eventually raises the possibility of safety violations. The dependability of fireproofing measures could be significantly increased by making investments in more sophisticated fire testing facilities and putting real-world simulation-based evaluations into practice.”
Monga, however, feels that infrastructure isn’t the only issue. India, in fact, has some well-equipped institutions, including the Central Building Research Institute (CBRI) and the Vimal Fire Training Center in Baroda, which are capable of conducting large-scale fire resistance assessments and offer comprehensive fire safety training.
The real challenge, according to him, is the reluctance to spend on fire safety. “Despite having access to advanced testing facilities, the priority often shifts to cost-cutting, leading to only the most basic fire protection measures being implemented,” he says. This tendency to view fire safety as a checkbox rather than a critical aspect of design and construction puts both lives and property at serious risk.
Monga also underlines the role of real-time fire simulation as a vital life-saving tool. “Simulations can enhance emergency preparedness and reduce casualties by up to 90 per cent, especially in high-rise steel buildings where evacuation is more complex,” he explains. Beyond testing, he advocates for a more holistic approach — combining prevention, real-time testing, and protection through the use of Personal Protective Equipment (PPE), firefighting systems, and fire-resistant materials.
However, Monga points out a worrying trend: many organisations still take shortcuts, opting for quick certifications instead of investing in thorough training and robust safety systems. “Ironically, people spend lavishly on luxury homes or international holidays but hesitate to invest in something as crucial as fire safety,” he remarks. This mindset, both experts agree, needs to change.
Weighing the Risk
When it comes to fireproofing steel structures in India, a major hurdle lies not just in technology but in market dynamics and perception. According to Divekar, while fire-resistant materials and coatings are gradually becoming more available, their adoption still faces significant bottlenecks. “The challenge is threefold — high prices, limited local manufacturing, and a lack of skilled applicators,” he says.
Most high-quality fireproofing materials are imported, inflating their cost and limiting widespread use. On top of this, there is a noticeable gap in awareness and training among construction professionals. He stresses that improving local manufacturing, investing in R&D, and nurturing skilled personnel could go a long way in making these solutions more accessible and affordable.
Agrawal adds another layer to this issue, pointing out that cost is often the ultimate deciding factor in material selection. “Structural steel has so many advantages — it’s lighter, faster, and offers flexibility in design. But if concrete costs significantly less, developers in this price-sensitive market will stick with it. When you add the cost of fireproofing to an already more expensive steel structure, the price gap widens further.”
He suggests that engaging fire engineers early in the project could help optimise fireproofing, ensuring it is applied where necessary instead of blanket usage, but even this won’t completely bridge the cost difference with concrete. “That’s why steel finds favour mostly in commercial projects where speed and flexibility matter more. In the residential sector, where cost is king, concrete continues to dominate,” he points out.
Panduranga offers an industry insider’s view on the availability of fireproofing coatings. “For intumescent coatings, there is no shortage of options — AkzoNobel, Jotun, Carboline, and Isolatek are all active in the Indian market,” he says. However, vermiculite coatings tell a different story. “In this segment, choices are limited to Carboline, Isolatek, and Neukem. In fact, over the past year, we’ve had to import materials from Saudi Arabia, South Korea, or Dubai using brands like Promat and Bovia to meet project demands,” he shares.
Interestingly, he adds that the hesitation isn’t necessarily on the demand side. “People are open to using these materials, the issue is the supply chain, especially for vermiculite coatings, where demand often outstrips availability.” This supply gap, coupled with cost concerns, continues to hold back the widespread adoption of fireproofing solutions in India’s steel construction sector.
Enduring Heights
Durability in buildings, especially when it comes to fire protection, is often misunderstood. Agrawal highlights the prevailing misconception, “People tend to think that once a building is constructed, it’s set for life. But maintenance is critical, no matter what material you use.” Drawing from his experience working on a brownfield project over the past three to four years, he shares insights from the assessment of nearly 100 million sq ft of built-up area — covering 200 to 300 structures ranging from 10 to 40 years old. What surprised him most was the trend he observed, “In some cases, I’ve seen more deterioration in buildings just 10 years old than in those standing strong for over three decades. That clearly shows that durability is more a matter of workmanship than the material itself.”
Agrawal underlines the importance of regular structural inspections, especially for steel buildings. “Over time, intumescent coatings and fire bolts can degrade, reducing the structure’s fire resistance. Similarly, for concrete structures, if the protective cover deteriorates, the intended fire rating becomes meaningless.” He stresses that good maintenance and quality workmanship can significantly delay the onset of such issues. “With proper care, deterioration that might occur within three to four years could easily be pushed back to six or seven years or more,” he adds.
Panduranga further elaborates on the longevity of fireproofing systems, breaking down the two most common types: intumescent and vermiculite coatings. “Vermiculite is usually applied to beams and hard-to-reach areas since, unless compromised by water leakage or physical damage, it can last the entire life of the building,” he explains.
Intumescent coatings, on the other hand, are typically used on columns and require periodic maintenance. “But the maintenance needs vary,” Panduranga notes. “In well-maintained interiors, you might hardly need to do anything. Plus, these coatings come with a polyurethane topcoat — about 50 to 75 microns thick — so minor scratches or marks can be wiped away with a damp cloth.”
Looking at global trends, he emphasises that steel fire protection typically revolves around three systems: vermiculite coatings, intumescent coatings, and calcium silicate boards. “Calcium silicate boards are the most expensive, while vermiculite is the most economical. Intumescent coatings fall somewhere in between, offering a balance of fire safety and aesthetics,” he says. This aesthetic advantage is a key reason why architects often lean toward intumescent coatings, especially for structures where steel is left exposed and becomes a visible design feature. “Yes, it costs more, but the combination of safety and visual appeal makes it worth the investment,” he adds.
Drawing the Line
Integrating fireproofing into steel structures isn’t just about coating the steel, it often reshapes the entire design. “Steel is an excellent conductor of heat, which is why fire protection is non-negotiable,” explains Agrawal. However, adding fire protection can have unexpected implications. “Take fire boards, for example. They can add 100–200 mm to the soffit level, which, in turn, reduces the floor-to-ceiling height. Imagine a client aiming for 11 ft clear heights; suddenly, they find themselves with only 10.5 ft. That’s not a small compromise, especially in premium projects,” he says.
This often sparks a negotiation between the fire engineer, structural engineer, and architect. “The fire engineer will stand firm on safety requirements, while the structural engineer might have to resize beams or rework the structural system to recover the lost height without sacrificing strength,” Agrawal adds. These kinds of design revisions are quite common when working with steel.
Panduranga highlights another technical aspect. “The required thickness of fireproofing coatings depends on what’s called the ‘section factor,’ essentially, the relationship between the surface area exposed to fire and the mass of the steel member.” A thicker steel section naturally demands less coating, while thinner sections may require more. However, there’s a catch. “For very thin sections, like 6 mm plates, we sometimes face a lack of certified test data for achieving higher fire ratings, say, two hours, which limits design flexibility.”
This makes optimising both the steel section size and the fireproofing layer a delicate balancing act. “For sections around 8 to 10 mm, we usually manage to find a sweet spot where we can achieve the required fire resistance without incurring prohibitive costs,” he adds.
Next-Level Safety
When it comes to addressing common fireproofing challenges, Panduranga shares a practical insight, “One effective solution is actually to avoid using primers altogether. One of the major problems with SFRM (Sprayed Fire-Resistive Material) or vermiculite coatings is bonding failure between the steel and the fireproofing. But when there’s no primer, bonding tends to improve naturally, in fact, a light rust layer can enhance adhesion.” This isn’t just a workaround; it’s an industry-accepted approach. “The American Steel Association even recommends skipping primers for internally concealed steel protected by vermiculite coatings,” he adds, noting that it simplifies application and boosts reliability.
He also highlights a shift in testing standards. “We’ve been working with intumescent coatings based on BS 476 Part 21. Labs like Warrington, BRE, and AP+ test different steel sections to determine the necessary coating thickness to achieve fire resistance at critical temperatures.”
However, recent changes may reshape this familiar process. “The BS standard has now been replaced by the EN standard, and early indications suggest that it could be more stringent. This will likely have an impact on the required Dry Film Thickness (DFT), possibly increasing costs, although we’re still waiting to fully understand the implications,” he says.
Divekar emphasises the need for India to align more closely with international practices. “Performance-Based Design (PBD) is widely used globally to deliver tailored fire safety solutions based on the building’s use and risk profile,” he says. Beyond structural design, real-time fire monitoring, automated sprinklers, and smart detection systems can significantly enhance emergency response times.
He also points to retrofitting as an underused but effective strategy. “Global cities often have mandatory retrofitting codes for older buildings, which ensure long-term fire safety — something India could benefit from adopting.”
He further suggests looking at hybrid solutions. “Steel structures paired with fire-resistant materials like Cross-Laminated Timber (CLT) not only improve fire performance but also contribute to sustainability. With the right mix of advanced design strategies and stronger local regulations, India can make its high-rises safer and more future-ready.”
As steel reaches ever higher into India’s skies, the question is no longer whether we can build tall but whether we can build safe. The path ahead lies not just in architectural ambition, but in the commitment to fire-resilient design. The future skyline will not only be defined by its height, but by the unseen layers of protection that give it strength, security, and longevity.
Quote
“Developers have a critical responsibility to ensure that their security guards receive comprehensive training in firefighting, evacuation procedures, and fire safety protocols.”
– Deepak Monga, Fire Safety and Evacuation Expert
“Global cities often have mandatory retrofitting codes for older buildings, which ensure long-term fire safety — something India could benefit from adopting.”
– Sameer Divekar, Executive Vice President, CP Kukreja Architects
“Intumescent paint or other fire-resistant materials can be used on columns, while horizontal members like steel beams can be protected by installing a false ceiling with fire-resistant boards.”
– Shrirang Agrawal, Sr Structural Engineer, Arup
“People are open to using [fireproofing] materials, the issue is the supply chain, especially for vermiculite coatings, where demand often outstrips availability.”
– Praveena Panduranga, Head – Structural Steel Fireproofing, JSSL
