EMULTEX: The Brand for Intumescent Binders

Based on decades of service

(Technical bulletin 2204)
Intumescent paints
An area of growing importance
1. The majority of multi-storied high-rises today have a steel skeleton. Load-bearing
steel structures are a key concern for building authorities.
2. Although steel does not burn, it is has to be protected against fire. When
structural steelwork reaches a critical temperature, it can lose its load bearing
capability and buckle or collapse, with drastic consequences for the stability of
the building it is supporting.
3. Without proper protection of the steelwork it may bend and collapse within
minutes at temperatures above 500C.
4. Thus the extra time provided by intumescent coatings (means a swelling up or
expansion - one which expands when in contact with heat) slows and even
potentially prevents this destruction process.
5. In the past a protection time of 30 60 minutes was seen as sufficient, but new
standards increasingly require 90 120 minutes, which require highly specialised
binders.

(Data: Clariant)

Intumescent products are available as paints and coatings which are applied to
protect a whole variety of materials, including steel structures, metal sheets, wood,
plaster and concrete. In this brochure only coatings for steel structures are described.
How it works
The intumescent reaction is activated by heat at approximately 200C. It is an
endothermic reaction that absorbs heat, emits inert gases and creates an effective
insulation layer. Depending on the composition, such an intumescent coating will
swell up 10 to 100 times in thickness to build a foam char barrier that insulates the
underlying material.
This intumescent process may be divided into different steps, dependant on the
specialist raw materials used:
1. At temperature of 250C the thermoplastic binder (e. g. EMULTEX FR 728)
melts to form a soft matrix in which further thermochemical reactions can take
place.
2. Ammonium polyphosphate (acid donor), which is the major ingredient of the
intumescent coating, decomposes generating polyphosphoric acid.
3. This polyphosphoric acid reacts with a carbon donor (usually pentaerythrol or
dipentaerythrol) to form an inorganic/organic ester.
4. A blowing agent (e.g. melamine) decomposes and releases gases allowing
the molten resin and ester to create a foam that forms an insulating barrier
which adheres to the steel.
5. When the temperature keeps rising, the ester decomposes to form a tough
carbon char.

The resulting char insulates the substrates against heat. Thus, the protection time for
the steel structure depends on the quality (density, adhesion) and thickness of the
char.

The right choice of the binder in such an intumescent coating is crucial, because only
special binders are effective in forming a stable matrix, which results in a stable foam
and char.
Some other functional raw materials may be used to improve the performance:

TiO2 is used as pigment and as catalyst for the char formation. Thus the
choice of the right TiO2 is essential.

Flame retardants may be used in order to reduce spread of flame rate and
give self-extinguishing properties to the coating. (Emultex 5535 already
contains a flame retardant.)
In addition Melamine, used as blowing agent, is a nitrogen based flame
retardant which can show excellent flame retardant properties.

In combination with phosphorous synergists, melamine can further increase

char stability through formation with nitrogen-phosphorous substances.
Melamine can act as blowing agent for the char, enhancing the heat barrier
functionality of the char layer.

Addition of Lapinus fibres may improve drying properties of the paint (e. g. less
mud cracking, higher low shear viscosity), also improve stability of the char.
During the violent conditions of a fire, a fibre reinforced char will last for a
longer period of time and increase the performance of the intumescent
coating.

(Data: Lapinus Fibres based on a simplified paint formulation)

Emultex binders for intumescent coatings
Emultex 523
The market standard for 30 - 60 minutes protection
Rapid foam generation
Emultex FR 728
APEO-free alternative to Emultex 523
Rapid foam generation for up to 60 minutes intumescent coatings
Emultex 5535
TCPP plasticized PVAc homopolymer
Emultex FR 797
Slow developing compact foam.
Good water resistance
For protection time up to 120 minutes
Emultex FR 737
Slow developing compact foam.
For protection time up to 120 minutes
Emultex FR 747
Self-crosslinking polymer to give stable, compact foam and high durability.
Particularly suitable for 90 and 120 minutes performance
Viscosity [mPa*s]3
Solid Content [%]1

pH Value2

MFFT [C]
Tg [C]

Product Name Emulsion Properties*

Emultex 523 50.0 4.5 3,500 23 13
Emultex 5535 59.5 4.5 6,500 23 3
Emultex FR 728 50.0 4.0 2,200 23 13
Emultex FR 737 55.0 5.0 1,000 16 14
Emultex FR 747 55.0 4.5 1,000 16 14
Emultex FR 797 55.0 4.5 1,100 13 2
Notes: 1) According to ISO 3251 3) According to ISO 2555 (Brookfield)
2) According to ISO 976
* Data describe typical properties - not product specifications
Starting formulation

Intumescent coating based on Emultex FR 728

Pos. Ingredients Supplier pbw

1 Water 10.0
2 Dispex G40 BASF 0.3
3 Acticide MV Thor 0.2
4 Agitan 218 Mnzing 0.2
5 Natrosol 250 HBR Ashland 0.2
6 Ammonia 0.1
7 Optigel CK Rockwood 0.2
8 Tiona 595 Millenium 4.6
High Speed Disperse for 15 minutes
9 Water* 22.0

10 Dipentaerythritol** Perstorp 11.0

11 Melamine** DSM 11.0
12 Exolit AP422** Clariant 22.0

13 Butyl Diglycol Acetate*** 1.0

14 Emultex FR 728*** Synthomer 17.2
100.0

* Water added to cool grind

**For step 10, 11, 12: add and mix. Do not allow to heat up
***Step 14 and 15: let down.

Test Data
Viscosity (Stormer) 105Ku
Starting formulation

Intumescent coating based on Emultex FR 728

(with Lapinus fibres)
Pos. Ingredients Supplier P.B.W.
1 Water 14.30
2 Dispex G40 BASF 0.30
3 Acticide MV Thor 0.20
4 Agitan 218 Mnzing 0.20
5 Ammonia 0.10
6 Tiona 595 Millenium 14.00
High Speed Disperse for 15 minutes
Then allow to cool.
7 Charmor DP 15( Dipentaerythritol)** Perstorp 11.30
8 Melamine** DSM 12.20
9 Exolit AP422** Clariant 28.50
10 Xanthan gum (5% in water) 1.00
11 Butyl Diglycol Acetate*** 1.00
12 CF 10 (fibres) Lapinus Fibres 6.00
13 Emultex FR 728*** Synthomer 18.70
107.60

*For step 7-11: add and mix. Do not allow to heat up

**Step 12 and 13: let down.
Leading in emulsions and speciality polymers
Synthomer is one of the worlds leading suppliers of emulsion and speciality polymers
supporting leadership positions in many market segments including coatings, construction,
technical textiles, adhesives, paper and synthetic latex gloves. Our strategy is based first and
foremost on customer service provided worldwide through a strong network of local sales
and technical service, supported by regional application development and production in our
key markets. The company has its headquarters in Harlow, UK and provides customer
focused services from operational centres in Harlow (UK), Marl (Germany), Kuala
Lumpur (Malaysia), Shanghai (China), Dubai (UAE) and Durban (South Africa). We supply our
customers from more than 20 manufacturing sites across the world. We deliver the right
formula, globally, individually.

This information and our technical advice whether verbal, in writing or by way of trials are given in good
faith but without warranty, and this also applies where proprietary rights of third parties are involved. Our
advice does not release you from the obligation to verify the information currently provided especially that
contained in our safety data and technical information sheets and to test our products as to their suitability
for the intended processes and uses. The application, use and processing of our products and the products
manufactured by you on the basis of our technical advice are beyond our control and, therefore, entirely your
own responsibility. Our products are sold in accordance with the current version of our General Conditions of
Sale and Delivery.

Group Headquarters: Operational Centre Europe:

Synthomer plc Synthomer Deutschland GmbH
Central Road Werrastrae 10
Templefields 45768 Marl
Harlow, Essex Germany
CM20 2BH Phone +49 23 65 49-2552
United Kingdom info@synthomer.com
Phone: +44 1279 436 211

2013-08-07