Hook: When every second counts, fire protection becomes the last line of engineering defence.
Intro:
In today’s steel-driven architecture, fire safety has evolved far beyond the realm of codes and compliance. It now represents the true test of structural resilience, the defining factor between survival and collapse. At the forefront of this mission is Hempel Paints (India) Pvt. Ltd., bringing science, precision, and global expertise to the next generation of fire-resistant intumescent coatings. Through advanced testing, innovative formulations, and close collaboration with industry stakeholders, Hempel is demonstrating how real-world fire protection goes beyond compliance, towards performance, longevity, and trust.
While standardised fire tests are critical to certification, real-life fires don’t always play by the rulebook. “Every fire scenario is different,” explains Sudeep Makar, BDM, Infra & POEM, Hempel Paints (India) Pvt Ltd. “Standard fire tests use controlled, fully developed fires to assess coating performance. But in real situations, variables such as ventilation, fuel load, and heat flux differ dramatically.”
Interestingly, while these standards often produce conservative results, Makar notes that this conservatism introduces extra robustness into the final solution. In essence, a coating that passes stringent lab tests has already demonstrated its endurance under far harsher conditions than most real-world fires might produce.
According to research by the National Fire Protection Association (NFPA), over 70 per cent of structural steel failures in fires occur due to rapid temperature escalation rather than sustained exposure, underscoring why accurate thermal performance and coating expansion reliability are crucial for intumescent systems.
STANDING UP TO NATURE’S EXTREMES
It is not enough for coatings to perform in fire; they must also survive decades of environmental exposure. Hempel’s fire-resistant coatings are designed to maintain stability even under challenging atmospheric conditions.
Their solvent-borne intumescent systems, when paired with the right primers and topcoats, can withstand C4 environments (per ISO 12944), ensuring protection in areas prone to moderate industrial exposure and coastal influences. Meanwhile, their flagship Hempafire Extreme 550, an epoxy-based intumescent, is engineered for C5 conditions, suitable for offshore and highly corrosive industrial atmospheres. It is one of the few coatings globally capable of this performance.
“Durability is the foundation of safety. A fire coating is only as strong as its ability to last unscathed through humidity, temperature swings, and corrosion,” notes Makar. Notably, Hempafire Extreme 550 can be used with or without a primer up to C3 conditions, making it one of the most flexible fire-protection coatings available for both architectural and industrial steelwork.
TESTING TO THE LIMITS
At the core of Hempel’s fire protection R&D lies a commitment to scientific validation. Each coating system of primer, intumescent, and topcoat undergoes full-scale testing on 1-m-long structural steel elements to verify adhesion, expansion, and protection consistency. Only when the system demonstrates synergy under fire load is it approved for real-world application.
This holistic testing method mirrors the complexity of an actual construction site, ensuring reliability under multidirectional stress and heat.
Beyond product innovation, Hempel continues to explore new materials and binder technologies to improve film integrity, speed of expansion, and char stability, three parameters that directly dictate performance during fire exposure.
THE REAL SECRET INGREDIENT
Fire protection fails in isolation and requires tight coordination among stakeholders. Hempel maintains continuous engagement with consultants, EPC contractors, and applicators to ensure correct surface preparation, coating thickness, and specification alignment.
“Depending on the project stage, our team works hand-in-hand with consultants and applicators to ensure the right fire rating is achieved and sustained,” says Makar. This proactive collaboration ensures the coating’s performance is never compromised, whether it is an airport, a refinery, or a steel-intensive commercial complex.
SETTING THE RECORD STRAIGHT
One of the most common misconceptions, Makar points out, is the confusion between fire protection and heat resistance. “Our intumescent coatings are engineered for R-type fire protection, that is, structural fire resistance. They are not substitutes for high-heat resistant coatings used in furnaces or process equipment.”
This distinction, though often overlooked, is critical for consultants and fabricators specifying the right system. The right coating in the wrong application can nullify both compliance and performance.
WHY FIRE COATINGS MATTER MORE THAN EVER
With global data centers, oil refineries, and manufacturing parks emerging across India, the stakes for fire-resistant coatings have never been higher. The Indian fire safety coatings market, valued at USD 120 million in 2024, is expected to grow at over 8 per cent CAGR through 2030. This growth is propelled by stricter safety norms, insurance-driven performance requirements, and the increasing use of exposed steel architecture in commercial and industrial projects.
Intumescent coatings today are not just protective layers; they are smart materials engineered to react under crisis, expanding up to 50 times their original thickness when exposed to heat, insulating the steel beneath from reaching its critical failure temperature of 550°C.
“A fire coating’s true value is tested not in the lab, but in the moments that decide structural survival.”
— Sudeep Makar
Hempel’s Flagship Fire Protection System
Product: Hempafire Extreme 550
Type: Epoxy Intumescent Coating
Designed For: Structural steel in onshore/offshore environments
Corrosivity Rating: Up to C5 (ISO 12944)
Primer/Topcoat Requirement: Optional (varies by environment)
Key Benefits:
- Ultra-high char stability and rapid expansion under fire
- Excellent corrosion resistance for long-term durability
- Reduced film thickness and faster application cycles
- Certified performance through full-scale fire testing
Editor’s Note:
As India’s built environment evolves toward smarter, greener, and safer structures, fire protection must evolve beyond compliance. Hempel’s focus on scientific validation, environmental durability, and real-world performance exemplifies the industry’s new direction, where coatings are not mere finishes but vital engineering components safeguarding human life and infrastructure.
