Eco-Friendly Polymer Nanocomposite Coatings for Next-Generation Fire Retardants for Building Materials.

The increasing global commitment to carbon neutrality has propelled a heightened focus on sustainable construction materials, with wood emerging as pivotal due to its environmental benefits. This review explores the development and application of eco-friendly polymer nanocomposite coatings to enhance wood's fire resistance, addressing a critical limitation in its widespread adoption. These nanocomposites demonstrate improved thermal stability and char formation properties by integrating nanoparticles, such as nano-clays, graphene oxide, and metal oxides, into biopolymer matrices. This significantly mitigates the flammability of wood substrates, creating a robust barrier against heat and oxygen. The review provides a comprehensive examination of these advanced coatings' synthesis, characterization, and performance. By emphasizing recent innovations and outlining future research directions, this review underscores the potential of eco-friendly polymer nanocomposite coatings as next-generation fire retardants. This advancement supports the expanded utilization of wood in sustainable construction practices and aligns with global initiatives toward achieving carbon neutrality.

Research on Thermal Stability and Flammability of Wood Scob-Based Loose-Fill Thermal Insulation Impregnated with Multicomponent Suspensions.

Loose-fill thermal composite insulation produced from surface-modified wood scobs has been explored as a potential fire-resistant material for building envelopes. This work involves fire resistance behavior comparisons between four coating systems consisting of liquid glass, liquid glass-tung oil, liquid glass-expandable graphite, and liquid glass-tung oil-expandable graphite. The techniques of thermogravimetric and differential thermogravimetric analyses, gross heat combustion via a calorimetric bomb, cone calorimetry, SEM imaging of char residues, and energy dispersive spectrometry for elemental analysis, as well as propensity to undergo continuous smoldering, were implemented. The coating technique resulted in greater thermal stability at a higher temperature range (500-650 °C) of the resulting loose-fill thermal composite insulation, reduced flame-damaged area heights after the exposure of samples at 45° for 15 s and 30 s, with a maximum of 49% decreased gross heat combustion, reduced heat release and total smoke release rates, improved char residue layer formation during combustion and changed smoldering behavior due to the formation of homogeneous and dense carbon layers. The results showed that the highest positive impact was obtained using the liquid glass and liquid glass-expandable graphite system because of the ability of the liquid glass to cover the wood scob particle surface and form a stable and strong expanding carbon layer.

Rational synthesis of methylsilsesquioxane aerogels addressing thermal load and compression recovery issues in Li-ion batteries.

Li-ion batteries suffer from two key safety issues: thermal overload and compression recovery, which may lead to flammability and mechanical failure. Silica aerogels are promising solutions to both these issues owing to their excellent thermal stability and tailored mechanical properties. However, finding the optimum sol composition in sol-gel-based aerogel synthesis is needed to address these issues at industry-relevant scales. Here, we propose an innovative approach to determine the optimum sol composition for methylsilsesquioxane (MSQ) aerogel sheets, which is based on the mechanisms of the effects of molar ratios of hydrolysis water and isopropyl alcohol (IPA) to methyltrimethoxysilane (MTMS) on the physical properties of MSQ aerogel sheets and according to the ternary contour distribution of their properties. The synthesized MSQ aerogels exhibited a soft, light, and powderless texture and featured superhydrophobic properties (150.2°), low thermal conductivity of 33.6 mW/(m·K), high thermal stability temperature in nitrogen atmosphere at 479.3 °C and moderate short-term (<6 h) service temperature of 120.0 °C. Significantly, the structural stability and elasticity of the aerogels surpassed the current state-of-the-art, showing recovery to 81.3 % of the original thickness and 85.2 % of the original stress after being subjected to 400 cycles of high-speed and high-strain consecutive compression, respectively. These excellent properties make the MSQ aerogel sheets promising for applications in thermal load and compression recovery management of diverse energy storage devices, including batteries for next-generation electric vehicles.

Study of a Fire-Resistant Plate Containing Fly Ashes Generated from Municipal Waste Incinerator: Fire and Mechanical Characteristics and Environmental Life Cycle Assessment.

The recycling of fly ash from municipal solid waste incineration is currently a global issue. This work intends to examine the viability of a novel recycling alternative for fly ashes as a component of fire-resistant plates. To lessen the quantity of heavy metal leaching, the fly ash was utilized after being washed using a water/fly ash ratio of 2 for one hour. Subsequently, an inexpensive, straightforward molding and curing process was used to create a plate, with a composition of 60%wt of MSWI-FA, 30%wt of gypsum, 0.5%wt of glass fiber and 9.5%wt of vermiculite. The plate exhibited high fire resistance. Furthermore, it demonstrated compression, flexural strength and surface hardness slightly lower than the requirements of European Standards. This allows for manufacturing plates with a high washed MSWI-FA content as fire protection in firewalls and doors for homes and commercial buildings. A Life Cycle Assessment was carried out. The case study shows that a 60% substitution of gypsum resulted in an environmental impact reduction of 8-48% for all impact categories examined, except four categories impacts (marine eutrophication, human toxicity (cancer), human non-carcinogenic toxicity and water depletion, where it increased between 2 and 718 times), due to the previous washing of MSWI-FA. When these fly ashes are used as a raw material in fire-resistant materials, they may be recycled and offer environmental advantages over more conventional materials like gypsum.

Biomimetic Nanoporous Transparent Universal Fire-Resistant Coatings.

The inherent flammability of most polymeric materials poses a significant fire hazard, leading to substantial property damage and loss of life. A universal flame-retardant protective coating is considered as a promising strategy to mitigate such risks; however, simultaneously achieving high transparency of the coatings remains a great challenge. Here, inspired by the moth eye effect, we designed a nanoporous structure into a protective coating that leverages a hydrophilic-hydrophobic interactive assembly facilitated by phosphoric acid protonated amino siloxane. The coating demonstrates robust adhesion to a diverse range of substrates, including but not limited to fabrics, foams, paper, and wood. As expected, its moth-eye-inspired nanoporous structure conferred a high visible light transparency of >97% and water vapor transmittance of 96%. The synergistic effect among phosphorus (P), nitrogen (N), and silicon (Si) largely enhanced the char-forming ability and restricted the decomposition of the coated substrates, which successfully endowed the coating with high fire-fighting performance. More importantly, for both flexible and rigid substrates, the coated samples all possessed great mechanical properties. This work provides a new insight for the design of protective coatings, particularly focusing on achieving high transparency.

Fire Resistance of Foamed Concrete for Discontinuous Partition Filling.

Lightweight concrete exhibits many advantages over traditional concrete such as lower density and thermal conductivity and an easier, cheaper, less energy-consuming manufacturing process. In order to extend its applications, there is a need to study its behavior in fire situations. Due to that, the aim of this study was to assess the fire resistance of foam concrete, depending on its thickness and the foaming process applied. Fire resistance was assessed according to EN 1363-1. The results indicate the usefulness of foam concrete in terms of isolating fire temperatures for discontinuous partition filling that are consequently a real alternative to dedicated solutions in the field of passive fire protection. The density of foam concrete was shown to have a large effect on the ability to insulate fire temperatures with a standard material preparation process. It was also noted that changing the method to continuous foam feeding may result in the achievement of similar values while maintaining foam concrete low density.

Post-Heat Flexural Properties of Siloxane-Modified Epoxy/Phenolic Composites Reinforced by Glass Fiber.

The post-heat mechanical property is one of the important indices for the fire-resistance evaluation of fiber-reinforced polymers. At present, the primary approach to improving the post-heat mechanical property of a material involves incorporating inorganic fillers; yet, the enhancement is limited, and is accompanied by a reduction in room-temperature performance and processability. This study prepares glass-fiber-reinforced composites with elevated mechanical properties after heat through utilizing two variants of epoxy resins modified with polysiloxane, phenolic resin, kaolin, and graphite. In comparison to the phenolic samples, the phenylpropylsiloxane-modified epoxy resulted in a 115% rise in post-heat flexural strength and a 70% increase in the room-temperature flexural strength of phenolic composites. On the other hand, dimethylsiloxane-modified epoxy leads to a 117% improvement in post-heat flexural strength but a 44% decrease in the room-temperature flexural strength of phenolic composites. Macroscopic/microscopic morphologies and a residual structure model of the composites after heat reveal that, during high temperature exposure, the pyrolysis products of polysiloxane promote interactions between carbon elements and fillers, thus preserving more residues and improving the dimensional stability as well as the density of materials. Consequently, a notable enhancement is observed in both the post-heat flexural strength and the mass of carbon residue after the incorporation of polysiloxane and fillers into the materials. The pyrolysis products of polysiloxane-modified epoxy play a vital role in enhancing the post-heat flexural strength by promoting carbon retention, carbon fixation, and interactions with fillers, offering novel pathways for the development of advanced composites with superior fire-resistance properties.

Dataset on fire resistance analysis of FRP-strengthened concrete beams.

Machine learning (ML) has emerged as an efficient and feasible technique for tackling engineering problems. Despite the numerous advantages, the implementation of ML for evaluating the fire resistance of structural members is relatively scarce, primarily due to the lack of a reliable database with a substantial number of data points. To address this knowledge gap, this paper presents a comprehensive database on the fire performance of fiber reinforced polymer (FRP) strengthened reinforced concrete (RC) beams. The database comprises over 21,000 experimental and numerical data points with varying parameters, including various geometric dimensions, FRP-strengthening levels, steel reinforcement ratio, insulation thickness and configuration, material properties, and applied load levels. The database can be implemented to train ML algorithms for developing autonomous models for predicting the fire resistance of FRP-strengthened concrete beams with varying parameters.

Possibilities of Using Geopolymers in Welding Processes and Protection against High Temperatures.

Geopolymer materials have long been known for their competitive properties against traditional construction materials. Their special features include high resistance to elevated temperatures and good fire resistance. They are typically used as insulating materials at temperatures not exceeding 100 °C (because they can achieve a thermal conductivity coefficient of 0.060 W/m × K or less under these conditions). Still, they can also be used as thermal insulation at temperatures exceeding 1000 °C. One technology that uses very high temperatures is metal welding technology, where temperatures often exceed as many as 3000 °C. Geopolymers, due to their properties, can also be an interesting new alternative in various welding applications. This paper presents the preliminary results of pot-proofing the resistance of geopolymers to temperatures exceeding 3000 °C. Test results of a foamed geopolymer insulating a steel substrate are presented, and a geopolymer mold for thermite rail welding was made and realistically tested. The results confirmed the feasibility of using cast geopolymer molds for thermite welding of railroad rails. The geopolymer material performed well during the test and no cracks or other damage occurred. The following article presents the potential of using geopolymer materials for welding applications.

Influence of Waste Glass Addition on the Fire Resistance, Microstructure and Mechanical Properties of Geopolymer Composites.

Nowadays, humanity has to face the problem of constantly increasing amounts of waste, which cause not only environmental pollution but also poses a critical danger to human health. Moreover, the growth of landfill sites involves high costs of establishment, development, and maintenance. Glass is one of the materials whose recycling ratio is still insufficient. Therefore, in the presented work, the influence of the particle size and share of waste glass on the consistency, morphology, specific surface area, water absorption, setting time, and mechanical properties of geopolymers was determined. Furthermore, for the first time, the fire resistance and final setting time of such geopolymer composites were presented in a wide range. Based on the obtained results, it was found that the geopolymer containing 20% unsorted waste glass obtained a final setting time that was 44% less than the sample not containing waste glass, 51.5 MPa of compressive strength (135.2% higher than the reference sample), and 13.5 MPa of residual compressive strength after the fire resistance test (164.7% more than the reference sample). Furthermore, it was found that the final setting time and the total pore volume closely depended on the additive's share and particle size. In addition, the use of waste glass characterized by larger particle sizes led to higher strength and lower mass loss after exposure to high temperatures compared to the composite containing smaller ones. The results presented in this work allow not only for reducing the costs and negative impact on the environment associated with landfilling but also for developing a simple, low-cost method of producing a modern geopolymer composite with beneficial properties for the construction industry.

Construction of Multifunctional Hierarchical Biofilms for Highly Sensitive and Weather-Resistant Fire Warning.

Multifunctional biofilms with early fire-warning capabilities are highly necessary for various indoor and outdoor applications, but a rational design of intelligent fire alarm films with strong weather resistance remains a major challenge. Herein, a multiscale hierarchical biofilm based on lignocellulose nanofibrils (LCNFs), carbon nanotubes (CNTs) and TiO2 was developed through a vacuum-assisted alternate self-assembly and dipping method. Then, an early fire-warning system that changes from an insulating state to a conductive one was designed, relying on the rapid carbonization of LCNFs together with the unique electronic excitation characteristics of TiO2. Typically, the L-CNT-TiO2 film exhibited an ultrasensitive fire-response signal of ~0.30 s and a long-term warning time of ~1238 s when a fire disaster was about to occur, demonstrating a reliable fire-alarm performance and promising flame-resistance ability. More importantly, the L-CNT-TiO2 biofilm also possessed a water contact angle (WCA) of 166 ± 1° and an ultraviolet protection factor (UPF) as high as 2000, resulting in excellent superhydrophobicity, antifouling, self-cleaning as well as incredible anti-ultraviolet (UV) capabilities. This work offers an innovative strategy for developing advanced intelligent films for fire safety and prevention applications, which holds great promise for the field of building materials.

Fire Resistance of Fire-Protected Reinforced Concrete Beams Strengthened with Externally Bonded Reinforcement Carbon Fibre-Reinforced Polymers at the Full Utilisation Degree.

The fire resistance of reinforced concrete (RC) beams strengthened with externally bonded reinforcement carbon fibre-reinforced polymers (EBR CFRP) depends on the load level and degree of strengthening. Design guides for this type of structure recommend strengthening limits to prevent collapse of the structure due to vandalism, damage or fire. In practice, however, it is not uncommon to exceed the proposed limits. This necessitates protection of the CFRP adhesive against high temperatures, namely glass transition temperature levels. This paper presents the results of 10 full-scale experimental fire resistance tests of reinforced concrete beams with EBR CFRP strengthening, with and without fire protection and under various load levels including full utilisation. It was demonstrated that in cases where CFRP strengthening was not needed to carry load in an accidental fire scenario, test specimens with and without it achieved the same fire resistance. It was also proven that in cases where CFRP failure influenced the failure of the entire beam, fire protection was crucial for maintaining the beam's load-bearing capacity and its thickness had to be substantial. A fire resistance rating of over 4 h was achieved, nevertheless.

Fire resistance of low alloy Q420d high-strength steel column under high-temperature creep.

The high-temperature mechanical and creep characteristics of Q420D steel are investigated in this essay. To determine the steel's high-temperature yield strength, the high-temperature tensile test of Q420D steel was first performed. In the temperature range of 400°C-800°C, the high-temperature creep test under various pressures was conducted, and the creep strain curve over time was produced. Finite element analysis and comparison were done to examine the impact of creep strain on the Q420D steel column's bearing capacity under high-temperature conditions. The findings demonstrated that: Using Abaqus, a finite element fire resistance analysis of a Q420D steel column, was conducted while taking initial geometrical flaws, residual stress, and creep effect into account. As a result, the critical temperature of a Q420D steel column under various load ratios was determined. The largest deviation from the critical temperature in the standard GB51249-2017 was 2.9% when the creep effect was taken into account under the load ratio R = 0.3. The highest reduction in fire resistance limit time under low load ratio conditions, taking into account the creeping impact of Q420D steel columns, is 35%. The findings demonstrate that the high-temperature creep energy greatly lowers the steel column's fire resistance.

Fireproof Nanocomposite Polyurethane Foams: A Review.

First introduced in 1954, polyurethane foams rapidly became popular because of light weight, high chemical stability, and outstanding sound and thermal insulation properties. Currently, polyurethane foam is widely applied in industrial and household products. Despite tremendous progress in the development of various formulations of versatile foams, their use is hindered due to high flammability. Fire retardant additives can be introduced into polyurethane foams to enhance their fireproof properties. Nanoscale materials employed as fire-retardant components of polyurethane foams have the potential to overcome this problem. Here, we review the recent (last 5 years) progress that has been made in polyurethane foam modification using nanomaterials to enhance its flame retardance. Different groups of nanomaterials and approaches for incorporating them into foam structures are covered. Special attention is given to the synergetic effects of nanomaterials with other flame-retardant additives.

Surface Treatment of Mongolian Scots Pine Using Phosphate Precipitation for Better Performance of Compressive Strength and Fire Resistance.

Wood, as a naturally green and environmentally friendly material, has been widely used in the construction and decoration industries. However, the flammability of wood poses serious safety problems. To improve the fire resistance of wood, In this study, it is proposed to use calcium chloride (CaCl2) and disodium hydrogen phosphate (Na2HPO4, DSP) to impregnate wood for multiple cycles. The experimental results show that phosphate mineral precipitation can be deposited on the surface of the wood. Scanning electron microscopy (SEM) and X-ray diffraction (XRD) are used to analyze the micromorphology of mineral precipitation and use the MIP test to analyze the treated wood pore structure. The results show that with the increase in the number of cycles, the phosphate deposited on the surface of the wood increases, and the cumulative pore volume and water absorption rate of the wood after 10 cycles are 54.3% and 13.75% lower than that of untreated wood respectively. In addition, the cone calorimeter (CONE) confirmed that the total heat release (THR) and total smoke production (TSP) of wood treated in 10 cycles have decreased by 48.7% and 54.2% respectively compared with the untreated wood. Hence, this treatment method not only improves the mechanical properties of wood. It also improves fire resistance.

Fire Resistance Evaluation of Concrete Beams and Slabs Incorporating Natural Fiber-Reinforced Polymers.

This paper presents a numerical study to evaluate the fire resistance of concrete beams and slabs incorporating natural fiber-reinforced polymers (FRP). A validated finite element model was applied to carry out a series of numerical studies on fire-exposed reinforced concrete (RC) beams and slabs strengthened with conventional and bio-based FRP composites. The model calculates the temperature-dependent moment-curvature relationship for various segments of the member at each time step, which are then used to calculate the moment capacity and deflection of the member. The variables in the beams and slabs include different strengthening techniques (externally bonded FRP and near-surface mounted FRP), different fiber composites, and fire insulation schemes (uninsulated and insulated). The results from the study indicate that the bio-based FRP-strengthened RC members undergo a faster degradation in moment capacity and also experience higher deflections under fire exposure. This leads to a lower fire resistance in RC members with bio-based FRP composites compared to beams and slabs with conventional FRP-strengthened concrete members. The addition of fire insulation to the bio-based FRP-strengthened members can enhance their fire performance and help achieve the required fire resistance ratings for use in building applications. In this study, the NSM CFRP-strengthened RC beams were found to have a fire resistance of 3 h without any fire insulation; however, the bio-based FRP-strengthened beams required a layer of vermiculite-gypsum-based fire insulation material (of about 25 mm) to achieve similar fire resistance.

The Morphology, Mechanical and Dynamic Properties, Fire Hazard and Toxicity of Chloroprene and Butadiene Rubber Composites Cross-Linked with Zinc.

This paper presents the influence of zinc on the cross-linking process, mechanical and dynamic properties, morphologies and balance of thermal degradation of blends containing chloroprene rubber (CR) and butadiene rubber (BR). The novel aspect of this research is a comprehensive approach presenting a new curing agent for the CR/BR blends to increase their cross-linking density and final properties, including non-flammability and low fire hazard. This is due to the need to find an alternative to zinc oxide, which is the standard curing agent for chloroprene rubber. The regulations of the European Union enforce a significant limitation on the use of this compound in elastomer technology, due to its harmful effect on aquatic organisms. In this paper, the CR/BR composites were cured with zinc and filled with natural silica fillers (sillitin or chalcedonite) or synthetic silica filler (aerosil). The investigation focused on the morphology characterization of the obtained compounds, their cross-linking degree, swelling, mechanical and dynamic properties, fire hazard and toxicity. The structure of cured CR/BR blends was characterized via scanning electron microscopy (SEM). The fire resistance studies were performed using cone calorimetry or oxygen index methods, whereas toxicity tests were performed with the use of the FB-FTIR (fluidized bed reactor coupled with FTIR analyzer) method. The results showed that obtained CR/BR products were characterized by satisfactory final properties. The properties determined by the oxygen index and cone calorimetry methods, including the behaviors of the tested CR/BR vulcanizates in fire conditions, showed that the produced compounds were characterized by a low fire hazard and can be classified as non-combustible rubber products. However, the toxicity of the decomposition products, determined at 450, 550 and 750 °C, was very high.

A Nitrogen-Rich DOPO-Based Derivate for Increasing Fire Resistance of Epoxy Resin with Comparable Transparency.

To endow synergistically epoxy resin (EP) with excellent fire resistance and high optical transparency, a nitrogen-rich DOPO-based derivate (named as FATP) was synthesized and incorporated into EP. It showed that the incorporation of the FATP reduced the fire hazard of the EP, as demonstrated by the fact that the EP/4% FATP blends gained a UL-94 V-0 rating and an LOI value of 35%, with the lowest values of the THR (86.7 MJ/m2), the PHRR (1059.3 kW/m2), and the TSP (89.6 MJ/m2). The presence of the FATP also reduced the thermal stability and the crosslinking density whilst improving the curing reaction and the storage modulus of the EP/FATP blends. The TG-FTIR spectra showed that •HPO/•PO free radicals and some nonflammable gases (HN3 and NH3) were produced during the pyrolysis, and the characterization (SEM, Raman spectroscopy, and XPS) of char residues confirmed that the FATP facilitated the formation of continuous and compact carbon layers of greater graphitization degree. It was thus concluded that the FATP played the flame-retardant roles in both the gas and condensed phases. Furthermore, the FREPs kept almost identical transparency as the pristine EP, and mechanical properties were also slightly enhanced. The FREPs presented in this work show promising applications in the fields of advanced optical technology.

Nano Boron Oxide and Zinc Oxide Doped Lignin Containing Cellulose Nanocrystals Improve the Thermal, Mechanical and Flammability Properties of High-Density Poly(ethylene).

The widely used high-density polyethylene (HDPE) polymer has inadequate mechanical and thermal properties for structural applications. To overcome this challenge, nano zinc oxide (ZnO) and nano boron oxide (B2O3) doped lignin-containing cellulose nanocrystals (L-CNC) were blended in the polymer matrix. The working hypothesis is that lignin will prevent CNC aggregation, and metal oxides will reduce the flammability of polymers by modifying their degradation pathways. This research prepared and incorporated safe, effective, and eco-friendly hybrid systems of nano ZnO/L-CNC and nano B2O3/L-CNC into the HDPE matrix to improve their physio-mechanical and fire-retardant properties. The composites were characterized using Fourier transform infrared spectroscopy, scanning electron microscopy, energy dispersive X-ray analysis, thermo-gravimetric analysis, differential scanning calorimetry, dynamic mechanical analysis, horizontal burning test, and microcalorimetry test. The results demonstrated a substantial increase in mechanical properties and a reduction in flammability. The scanning electron microscope (SEM) images showed some agglomeration and irregular distribution of the inorganic oxides.

Physical, Mechanical and Radiological Characteristics of a Fly Ash Geopolymer Incorporating Titanium Dioxide Waste as Passive Fire Insulating Material in Steel Structures.

This research analyzes whether a titanium dioxide waste (TiO2 waste) can be used as a source material for geopolymers with good fire resistance properties. Samples with different proportions were prepared, replacing fly ashes with titanium dioxide waste on geopolymers (0, 20, 30, 40 and 100% w/w). The activating solution has a Na2O/SiO2 molar ratio of 0.98. Physical (bulk density, moisture content and water absorption) and mechanical (superficial hardness and compressive strength) characteristics have been evaluated. In addition, their thermal behavior at high temperatures (fire resistance, compressive strength at elevated temperature and absorbed energy) has also been evaluated to see if they can be used as fire insulating materials. This work also studies the radiological activity of geopolymer materials. The replacement of FA with WTiO2 increases the bulk density due to its higher specific bulk density. The highest compressive strength values were obtained with a TiO2 waste content between 30 and 40% w/w. The compressive strength decreases at high temperatures, especially when more TiO2 waste is added. When the amount of TiO2 waste is increased, so is the plateau of evaporation, and this, in turn, increases the resistance to fire. Geopolymers containing FA and TiO2 waste do not present radiological problems, although, when the TiO2 waste is increased, the activity index of the geopolymer also rises.